Академический Документы
Профессиональный Документы
Культура Документы
001-EN
REV. 12/2014
PRODUCT GUIDE
1
GAS ENGINE GAS SENSOR GAS ENGINE SPARK IGNITION
ACCESSORIES REGULATION SYSTEMS MANAGEMENT PLUGS SYSTEMS
COPYRIGHT
The copyright for any material used in the MOTORTECH publications is reserved. Any duplication or use of objects such
as pictures or texts in other electronics or printed publications is not permitted without MOTORTECH's agreement.
TRADEMARK INFORMATION
MOTORTECH is not a part of nor affiliated with ALTRONIC®, CATERPILLAR®, CUMMINS®, WAUKESHA®. All OEM names and
part numbers shown are for reference purpose only. All trademarks, logos, and symbols used or shown in the MOTORTECH
publications are exclusive objects to the right of their owners and are used for reference purpose only.
TABLE OF CONTENTS
SYSTEMS
IGNITION
110 MOTORTECH XT-Plugs
36 Flange Versions
112 MOTORTECH XTL-Plugs
38 Externally Mounted
116 MOTORTECH MPC Spark Plugs
39 Integral Standard Versions
116 MOTORTECH ICP Spark Plugs
40 Integral High Energy Versions
117 DENSO® Spark Plugs
124 Accessories and Tools
42 TRIGGERING
44 Pickups 128 GAS ENGINE MANAGEMENT
PLUGS
SPARK
47 Pickup Leads
130 ALL-IN-ONE
48 Trigger Devices
134 DetCon20
50 Trigger Discs
137 PowerView3
52 Accessories
138 MOTORTECH AlphaRail − Wiring Rail System
MANAGEMENT
54 HIGH TENSION LEADS AND ACCESSORIES
GAS ENGINE
140 SENSOR SYSTEMS
56 High Tension Leads – PolyMotTM Style
142 MOTORTECH AlphaRail − Wiring Rail System
60 High Tension Leads
144 Sensor Harnesses
61 Unshielded Safety Leads for Shielded Spark Plugs
147 Oxygen Sensors
63 Unshielded Safety Leads for Conventional Spark Plugs
148 MAP/MAT Sensors
64 Accessories
149 Thermocouples
68 MOT-Blues – Shielded High Tension Leads
69 Conventional Shielded High Tension Leads
SYSTEMS
150 GAS REGULATION
SENSOR
70 Terminal Kits
152 VariFuel2
76 PRIMARY LEADS 158 VariStep
159 EmCon5
78 Shielded Primary Leads − for MOTORTECH AlphaRail
162 Throttles
80 Conventional Shielded Primary Leads
164 DUNGS® Gas Trains
REGULATION
82 EXTENSIONS
166 GAS ENGINE ACCESSORIES
GAS
176 INDEX
3
WELCOME TO MOTORTECH
Welcome!
MOTORTECH −
For those who fail to advance from what they have already achieved are quickly
overtaken by the ever-changing demands of the market. This is why it pays to be
innovative.
At MOTORTECH we have been working hard to meet the needs of our customers for
WE UPGRADE GAS ENGINES
almost 25 years. We always strive to be one decisive step ahead of the rest! This is
how we have proven ourselves worthy of being your qualified partner for stationary
gas engines. Therefore, it should come as no surprise that MOTORTECH places high
value in innovation, in research and in development. With over 200 employees,
more than 20% are now active in this dynamic area! The continuous new and further
developments of our product line for ignitions, controls and monitoring of the com-
bustion process, ensure maximum availability and efficiency of your gas engines.
With greater efficiency comes fewer emissions which is good for our environment.
An example of our innovative strength is our new line of performance ignition coils.
They were developed along with the new production technology used for manufac-
turing at MOTORTECH.
If you have any questions or concern, please feel free to contact us. We guarantee
you a solution for your gas engine.
Florian Virchow
Managing Director
4
BENEFITS
5
INNOVATIVE DESIGN AND PRODUCTS
Innovative Design
TAKE ADVANTAGE
Mechanical Products
Six high-tech CNC machining centers and other precision machines for processing
metal and plastic parts are available for the production of mechanical products. To
achieve the greatest reliability, we use state-of-the-art laser technology to weld and
mark parts. We often develop and build our own manufacturing equipment. There
OF EXPERIENCE!
are often no optimal production machines on the market to produce our special sys-
tem components that meet our rigorous standards. This means that we can produce
exactly those products our customers need.
Electronic Products
Our base modules are produced with state-of-the- art technology in small volume
production runs in Germany and are marketed worldwide. These conditions make
it possible to individually adapt the electronics to every engine type and set of re-
quirements. Just plug it in and the engine runs. Replacement parts and components
undergo extensive automatic test procedures and durability tests at MOTORTECH
prior to their application. Even the smallest system component must satisfy the
high quality requirements of our “Zero Failure Strategy”.
6
QUALITY
Certified Quality
Sales Partner
All MOTORTECH subsidiaries and distributors are trained on a regular basis by
experienced personnel to enable us to keep our comprehensive quality promise
to even our most distant customers.
QUALITY IS WHEN
7
MAINTENANCE, REPAIR, ON-SITE SERVICE
Service Team
Take advantage of MOTORTECH’s many years of technical expertise in maintenance,
WHEN THINGS GET HOT
repair and service. Our team participates in an ongoing training program and is
familiar with the technical and maintenance procedures of all commonly used
systems. Our technicians will perform know how repairs using the latest test inst-
ruments and tools, either at your company site or at our own workshops, even on
products that we did not produce.
Furthermore, to assure you with the best possible delivery anywhere in the world,
IS AT YOUR SITE QUICKLY!
8
COMPLETE SERVICE
Consultation
Customer Training
Shared knowledge is multiplied knowledge. Our extensive training program is spe-
cifically made for your technical and service employees. We can teach them about
new developments in gas engine technology, and we invite all interested persons to
discuss their experiences, either at our classrooms in Celle (Germany), New Orleans
(USA) or at in-house training events at your company facilities.
MOTORTECH –
9
10
IGNITION CONTROLLERS
Years ago, MOTORTECH has made the decision to become a key player in design and manufacturing of ignition
controls for the Global Industrial Gas Engine Business. A large engineering staff develops hard and software plat-
forms. Test facilities were put in place to stress our hardware by temperature, heat and vibration. Cooperation with
engine manufacturers, packagers and end users have led to specific designs and arrangements that will ensure
the best performance of the rotating equipment.
The new engine regulations and the growing biogas market, the developing mine gas industry and all other kinds
of alternative fuel applications have raised strong demands for high energy, extended spark duration and very pre-
cised timing. Coupled to the demand for lean burn strategies, efficiency and equipment availability MOTORTECH
was forced to look at high technology for the future.
11
IGNITION CONTROLLERS
NEW
MIC5
MOTORTECH IGNITION CONTROLLER
MOST
MOTORTECH OUTPUT STAGE TECHNOLOGY
Technical Data & Features • 1 Auxiliary Synchronization Output (ASO) which Interfaces
• 18 to 32 VDC supply voltage can support a detonation control system • CAN Bus 2.0b interface (CANopen protocol J1939)
• 20 ignition outputs (e.g. DetCon) or fuel injection pump controllers • RS485 interface (Modbus RTU)
• 250 VDC primary voltage • Ignition release input • USB 1.1 interface
• 500 mJ primary energy • Go/NoGo output
12
D
A 1
CAN CAN
DetCon20
MOTORTECH DETONATION CONTROL SYSTEM
0-5V / 4-20 mA
6 C
3 8
4
SYSTEMS
IGNITION
X
5 V W 2
Y
B
AlphaRail Z
7 MOTORTECH IGNITION RAIL SYSTEM
alternative
Description
- Trigger device V Camshaft
6 Pickup leads* W Crankshaft
7 1 ignition coil per cylinder* X Engine
8 1 primary lead/high tension lead Y Cylinder
per ignition coil* Z Harness to connect ignition rail and junction box
Pickup Arrangements
3-pickup arrangement for 4-stroke engines 1-pickup arrangement for 4-stroke engines 2-pickup arrangement for 2-stroke engines
1) Reset 1) Camshaft 1) Reset
Magnetic pickup (holes, pins, teeth, screws) Hall-Effect pickup (disc with magnets) Magnetic pickup (holes, pins, teeth, screws)
2) Speed alternative 2) Speed
Magnetic pickup (holes, pins, teeth, screws) 1) Camshaft Magnetic pickup (holes, pins, teeth, screws)
3) Camshaft Inductive pickup (disc with pins, screws,
Hall-Effect pickup (magnets) slots / trigger device)
alternative
3) Camshaft
Inductive pickup (pins, screws, slots)
13
IGNITION CONTROLLERS
MIC4
MOTORTECH IGNITION CONTROLLER
MOST
MOTORTECH OUTPUT STAGE TECHNOLOGY
Technical Data & Features • 1 Auxiliary Synchronization Output (ASO) which Interfaces
• 10 to 32 VDC supply voltage can support a detonation control system • CAN Bus 2.0b interface (CANopen protocol J1939)
• 8 / 16 ignition outputs (e.g. DetCon) or fuel injection pump controllers • RS485 interface (Modbus RTU)
• 250 VDC primary voltage • Ignition release input • USB 1.1 interface
• 300 mJ primary energy • Go/NoGo output
14
D
A 1
CAN CAN
DetCon20
MOTORTECH DETONATION CONTROL SYSTEM
0-5V / 4-20 mA
6 C
3 8
4
SYSTEMS
IGNITION
X
5 V W 2
Y
B
AlphaRail Z
7 MOTORTECH IGNITION RAIL SYSTEM
alternative
Description
- Trigger device V Camshaft
6 Pickup leads* W Crankshaft
7 1 ignition coil per cylinder* X Engine
8 1 primary lead/high tension lead Y Cylinder
per ignition coil* Z Harness to connect ignition rail and junction box
Pickup Arrangements
3-pickup arrangement for 4-stroke engines 1-pickup arrangement for 4-stroke engines 2-pickup arrangement for 2-stroke engines
1) Reset 1) Camshaft 1) Reset
Magnetic pickup (holes, pins, teeth, screws) Hall-Effect pickup (disc with magnets) Magnetic pickup (holes, pins, teeth, screws)
2) Speed alternative 2) Speed
Magnetic pickup (holes, pins, teeth, screws) 1) Camshaft Magnetic pickup (holes, pins, teeth, screws)
3) Camshaft Inductive pickup (disc with pins, screws,
Hall-Effect pickup (magnets) slots / trigger device)
alternative
3) Camshaft
Inductive pickup (pins, screws, slots)
15
IGNITION CONTROLLERS
CONTROLLER
MIC4 Series Ignition Controllers – Standard Versions – Light Duty – MIL Style Connectors
MOST
1 Connector
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage ASC Equivalent to
66.00.410-8 8 MIL Style 17 pole socket programmable via MICT not applicable
66.00.410-16 16 MIL Style 17 pole socket programmable via MICT not applicable
MIC4 Series Ignition Controllers – Standard Versions – Panel Mount – Plug Connector Style
MOST
2 Connector
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage ASC Equivalent to
66.00.400-8 8 Plug connector Plug connector programmable via MICT not applicable
66.00.400-16 16 Plug connector Plug connector programmable via MICT not applicable
MIC4 Series Ignition Controllers – Standard Versions – Heavy Duty – MIL Style Connectors
MOST
3 Connector
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage ASC Equivalent to
66.00.440-8 8 MIL Style 17 pole socket programmable via MICT not applicable
66.00.440-16 16 MIL Style 17 pole socket programmable via MICT not applicable
16
MIC4 Series Ignition Controllers – Shielded Output Harnesses1) for Light Duty and Heavy Duty Ignition Controllers
P/N Description Connector Length Equivalent to
95.40.217-L Output harness for MIC4 Light Duty and Heavy Duty ignition controllers 17 pole pin, 180° "L"= 15/25/50 ft.
1)
Customer has to supply flex conduit.
MIC4 Series Ignition Controllers – Special Version – Light Duty – MIL Style Connectors
MOST
Connector
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage ASC Equivalent to
SYSTEMS
IGNITION
66.00.411-8 8 MIL Style 10 pole pin 10 pole socket programmable via MICT not applicable MIC500 P/N 06.00.520
66.00.412-16 12 MIL Style 10 pole pin 14 pole socket programmable via MICT not applicable MIC500 P/N 06.00.525
66.00.413-16 16 MIL Style 10 pole pin 19 pole socket programmable via MICT not applicable MIC500 P/N 06.00.525
MIC850
66.00.414-161) 16 MIL Style 35 pole socket programmable via MICT not applicable
P/N 66.00.855-24/-24-D
WAUKESHA® CEC
10 pole VGF & VHP series 6 &
66.00.417-8 8 MIL Style 7 pole pin 10 pole pin programmable via MICT not applicable
socket 8 cyl.2) / MIC500 P/N
06.00.515-6/-8
WAUKESHA® CEC
VGF & VHP series 12 &
66.00.418-16 16 MIL Style 7 pole pin 10 pole pin 19 pole pin programmable via MICT not applicable
16 Cyl.2) / MIC500 P/N
06.00.516/517
MIC850
66.00.420-16 12 MIL Style 14 pole socket programmable via MICT not applicable
P/N 66.00.855-12/-12-D
6 pole 10 pole
66.00.421-16 16 MIL Style 19 pole socket programmable via MICT not applicable MIC500 P/N 06.00.510
socket socket
10 pole
66.00.422-16 16 MIL Style - 19 pole socket programmable via MICT not applicable MIC500 P/N 06.00.511
socket
1)
Maximum of 16 outputs available for this model.
2)
When replacing CEC controller by MIC4 use of DSM control is not possible.
17
IGNITION CONTROLLERS
CONTROLLER
MICT
MOTORTECH INTEGRATED CONFIGURATION TOOL
Parameter Set
The MIC4 offers two sets of parameters for the necessary inputs in
order to calculate the engine ignition timing, which e.g. can be used
for a two gas quality operation. Furthermore the parameter sets can
be visualized graphically.
Parameter Set – Configuration Visualisation Parameter Set – Energy Settings Breakdown Voltage
The graphic display of the parameter set A and B For start phase and normal operation of the engine, The MICT offers a lot of real time and detailed infor-
offers a fast, visual control of the configured values. durations at different high voltage levels and mation about the status of each individual ignition
ignition spark intensity can be adjusted with the output. Important data will be visually prepared,
advanced energy settings. so that any irregularities will stand out easily. For
example, secondary voltage will be displayed as bar
graph, and the type of misfiring carries a warning
light as symbol.
18
NEW
PowerView3 MOTORTECH ENGINE INFORMATION MONITOR
SYSTEMS
IGNITION
error diagnostics on-site without requiring a laptop!
Sample Screens
19
IGNITION CONTROLLERS
• Large built in LC-Display with keyboard (optional) • Print function of a given moment in the operation
in selectable languages can be used for external problem analysis via
• Access controlled E-Mail or any other data communication
20
MIC850 Series Ignition Controllers – HMI Module (optional)
The operating data of MIC850 ignition control devices will be the selftest for error diagnostics via HMI module can also be
completely visualised via HMI module (Human-Machine Inter- executed. 8 control keys guarantee simple navigation through
face). The overview sheet shows the relevant information. The different display pages and menus. All in all, the MIC850
MIC850 HMI module allows justification of various ignition HMI module is also able to provide error diagnostics on-site
parameters such as ignition timing and energy. Functions as without requiring a mobile PC!
SYSTEMS
IGNITION
Auto Spark Control Timing Schedule A
Display and adjustment options of the requested In this window you can adjust the reset position Overview of the ignition timing adjustment of
spark plug firing duration directly at the HMI- with the engine running. This is meant to compare configuration A. Here you can directly see whether
module. the ignition timing of the display with the one mea- ignition timing adjustment takes place via an
sured by timing light. analog input or via speed curve. The current ignition
timing will be displayed under „Global Timing“.
21
IGNITION CONTROLLERS
A 1
DetCon20
MOTORTECH DETONATION CONTROL SYSTEM
0-5V / 4-20 mA
6 C
3 8
4
5 V W 2
Y
B
AlphaRail Z
7 MOTORTECH IGNITION RAIL SYSTEM
alternative
A DetCon20 – Detonation controller
5 Trigger discs
alternative Description
per ignition coil* Z Harness to connect ignition rail and junction box
Pickup Arrangements
3-pickup arrangement for 4-stroke engines 1-pickup arrangement for 4-stroke engines 2-pickup arrangement for 2-stroke engines
1) Reset 1) Camshaft 1) Reset
Magnetic pickup (holes, pins, teeth, screws) Hall-Effect pickup (disc with magnets) Magnetic pickup (holes, pins, teeth, screws)
2) Speed alternative 2) Speed
Magnetic pickup (holes, pins, teeth, screws) 1) Camshaft Magnetic pickup (holes, pins, teeth, screws)
3) Camshaft Inductive pickup (disc with pins, screws,
Hall-Effect pickup (magnets) slots / trigger device)
alternative
3) Camshaft
Inductive pickup (pins, screws, slots)
22
MIC850 Series Ignition Controllers – Standard Versions – MIL Style Connectors
P/N max. Outputs Connector Output Connector Pickup Voltage HMI MOST Equivalent to
95.40.414-L Output harness for P/N 66.00.855-12/-12-D 14 pole pin, 90° "L"= 15/25/50 ft.
95.40.435-L Output harness for P/N 66.00.855-24/-24-D 35 pole pin, 90° "L"= 15/25/50 ft.
SYSTEMS
Customer has to supply flex conduit.
IGNITION
1)
66.00.851-24 24 MIL Style 14/17 pole socket 24 VDC not applicable WOODWARD® IC9xx
66.00.851-24-D 24 MIL Style 14/17 pole socket 24 VDC x not applicable WOODWARD® IC9xx
95.40.414-L Output harness for P/N 66.00.851-24/-24-D 14 pole pin, 90° "L"= 15/25/50 ft.
95.40.417-L Output harness for P/N 66.00.851-24/-24-D 17 pole pin, 90° "L"= 15/25/50 ft.
1)
Customer has to supply flex conduit.
23
IGNITION CONTROLLERS
24
RS232
A 1
D
DetCon20
MOTORTECH DETONATION CONTROL SYSTEM
4-20 mA
4 6 C
3 8
SYSTEMS
IGNITION
X
5 V 2
Y
B
AlphaRail Z
7
MOTORTECH IGNITION RAIL SYSTEM
alternative
Description
Trigger device V Camshaft
6 Pickup lead* W Crankshaft
7 1 ignition coil per cylinder* X Engine
8 1 primary lead/high tension lead Y Cylinder
per ignition coil* Z Harness to connect ignition rail and junction box
Pickup Arrangements
1- pickup arrangement for 4-stroke engines 1- pickup arrangement for 2-stroke engines
1) Camshaft 1) Reset
Hall-Effect pickup (disc with magnets) Magnetic pickup (holes, pins, teeth, screws)
alternative
25
IGNITION CONTROLLERS
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage MOST ASC Equivalent to
06.00.520 8 MIL Style 10 pole pin 10 pole socket 24 VDC not applicable not applicable
06.00.525 12 MIL Style 10 pole pin 14 pole socket 24 VDC not applicable not applicable
06.00.530 16 MIL Style 10 pole pin 19 pole socket 24 VDC not applicable not applicable
MIC500 Series Ignition Controllers – Non-Shielded Input Harnesses for Ignition Controllers P/N 06.00.520/525/530
P/N Description Connector Length Pickup
06.02.501-160 Input harness for P/N 06.00.520/525/530 10 pole socket, 180° 160 in. inductive
06.02.505-160 Input harness for P/N 06.00.520/525/530 10 pole socket, 180° 160 in. magnetic
06.02.510-160 Input harness for P/N 06.00.520/525/530 10 pole socket, 180° 160 in. hall-effect
MIC500 Series Ignition Controllers – Non-Shielded Output Harnesses for Ignition Controllers P/N 06.00.520/525/530
P/N Description Connector Length Outputs
06.02.608-240 Output harness for P/N 06.00.520 10 pole pin, 180° 240 in. 8
06.02.612-240 Output harness for P/N 06.00.525 14 pole pin, 180° 240 in. 12
06.02.616-240 Output harness for P/N 06.00.530 19 pole pin, 180° 240 in. 16
MIC500 Series Ignition Controllers – Shielded Input Harnesses for Ignition Controllers P/N 06.00.520/525/530
P/N Description Connector Wire Length Conduit Length Pickup
95.30.501-80 Input harness for P/N 06.00.520/525/530 10 pole socket, 180° 160 in. 80 in. inductive
95.30.505-80 Input harness for P/N 06.00.520/525/530 10 pole socket, 180° 160 in. 80 in. magnetic
95.30.510-80 Input harness for P/N 06.00.520/525/530 10 pole socket, 180° 160 in. 80 in. hall-effect
MIC500 Series Ignition Controllers – Shielded Output Harnesses for Ignition Controllers P/N 06.00.520/525/530
P/N Description Connector Wire Length Conduit Length Outputs
95.30.608-80 Output harness for P/N 06.00.520 10 pole pin, 180° 160 in. 80 in. 8
95.30.608-160 Output harness for P/N 06.00.520 10 pole pin, 180° 240 in. 160 in. 8
95.30.608-300 Output harness for P/N 06.00.520 10 pole pin, 180° 380 in. 300 in. 8
95.30.612-80 Output harness for P/N 06.00.525 14 pole pin, 180° 160 in. 80 in. 12
95.30.612-160 Output harness for P/N 06.00.525 14 pole pin, 180° 240 in. 160 in. 12
95.30.612-300 Output harness for P/N 06.00.525 14 pole pin, 180° 380 in. 300 in. 12
95.30.616-80 Output harness for P/N 06.00.530 19 pole pin, 180° 160 in. 80 in. 16
95.30.616-160 Output harness for P/N 06.00.530 19 pole pin, 180° 240 in. 160 in. 16
95.30.616-300 Output harness for P/N 06.00.530 19 pole pin, 180° 380 in. 300 in. 16
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage MOST ASC Equivalent to
combined combined
06.00.508 8 AMP Style 23 pole pin 24 VDC not applicable not applicable WOODWARD® IC100
with input with input
26
MIC500 Series Ignition Controllers – Non-Shielded Input and Output Harnesses for Ignition Controller P/N 06.00.508
P/N Description Connector Length Pickup
06.01.001-160 Input and output harness for P/N 06.00.508 23 pole socket, 180° 160 in. inductive
06.01.101-160 Input and output harness for P/N 06.00.508 23 pole socket, 180° 160 in. magnetic
06.01.301-160 Input and output harness for P/N 06.00.508 23 pole socket, 180° 160 in. hall-effect
P/N max. Outputs Connector Input Analog Input Output Pickup Voltage MOST ASC Equivalent to
SYSTEMS
IGNITION
10 pole WAUKESHA® CEC
06.00.515-61) 8 MIL Style 7 pole pin 10 pole pin 8 VDC not applicable not applicable
socket VGF & VHP series 6 cyl.2)
WAUKESHA® CEC
06.00.5161) 16 MIL Style 7 pole pin 10 pole pin 19 pole pin 8 VDC not applicable not applicable
VGF & VHP series 12 Cyl.2)
WAUKESHA® CEC
06.00.5171) 16 MIL Style 7 pole pin 10 pole pin 19 pole pin 8 VDC not applicable not applicable
VGF & VHP series 16 Cyl.2)
1)
Ignition controller comes preprogrammed.
2)
When replacing CEC-controller by MIC500 use of DSM control is not possible.
MIC500 Series Ignition Controllers – Non-Shielded Input Harnesses for Ignition Controllers P/N 06.00.513/514/515-6/515-8/516/517
P/N Description Connector Length Pickup
06.02.011-80 Input harness for P/N 06.00.513/514 6 pole socket, 180° 80 in. hall-effect
06.31.034-80 Input harness for P/N 06.00.515-6/515-8/516/517 7 pole socket, 180° 80 in. hall-effect
MIC500 Series Ignition Controllers – Non-Shielded Analog Input Harnesses for Ignition Controllers P/N 06.00.513/514/515-6/515-8/516/517
P/N Description Connector Length
06.71.047 Analog input harness for P/N 06.00.513/515-6/515-8 10 pole pin, 180° 160 in.
06.02.022-160 Analog input harness for P/N 06.00.514/516/517 10 pole socket, 180° 160 in.
MIC500 Series Ignition Controllers – Non-Shielded Output Harnesses for Ignition Controllers P/N 06.00.513/514/515-6/515-8/516/517
P/N Description Connector Length Outputs
06.31.035-160 Output harness for P/N 06.00.513/515-6/515-8 10 pole socket, 180° 160 in. 8
06.02.010-160 Output harness for P/N 06.00.514/516/517 19 pole socket, 180° 160 in. 16
06.05.040A RS232 ignition display for use with MIC500 series ignition controllers
27
28
IGNITION COILS
The demand for more specialized ignition coils has forced MOTORTECH to design and manufacture its own igniti-
on coil product lines. From standard EPOXY molded ignition coils to shell type high energy coils and very special
shielded and CSA certified versions, there is a wide variety of coils “Made in Europe“ available through the global
product distribution network.
Lean burn gas engines, high voltage measuring (MOST – MOTORTECH Output stage technology and ASC – Auto
Spark Control) or indicating systems (spark reference system) – all require very special coil characteristics. Not
only the design but also the manufacturing processes are important. MOTORTECH ignition coils today are manu-
factured in a semi automated process under vacuum and together with modern high speed winding equipment it is
ensured that one coil is like the other. Designed for the toughest applications and built to last.
29
IGNITION COILS
Non CSA Certified Ignition Coils – Standard Versions – New MOTORTECH Style
P/N Supersedes Color Primary Termination HV Termination Polarity ASC MOST Equivalent to
06.50.105 blue #10-32 UNF studs female (-) ground not applicable x
MOST
MOTORTECH OUTPUT STAGE TECHNOLOGY
100 MOST
CDI
Secondary Current [mA]
variable
30
Non CSA Certified Ignition Coils – Standard Versions – MOTORTECH Style
A large amount of different EPOXY ignition coils with different
ignition characteristics are available for non-shielded applications.
A variety of short and long duration coils with female, male
(SAE) or even screw type vspark plug lead termination allows
the operator to pick the best for his application.
MOTORTECH ignition coils are made to the highest quality stan-
dards. A constant improvement of the manufacturing process
has led to a product line that is unique when it comes to life
time and repeatability of high voltage pattern and performance.
06.50.001 consult factory black #10-32 UNF studs female (-) ground not applicable not applicable PPT2477P
06.50.002 06.50.001 black #10-32 UNF studs female (-) ground not applicable not applicable PPT2477L
SYSTEMS
IGNITION
06.50.003 06.50.007 black #10-32 UNF studs M6 (-) ground x not applicable
06.50.060 black #10-32 UNF studs M6 (-) ground not applicable not applicable
06.50.053 black #10-32 UNF studs female (+) ground not applicable not applicable 291001
06.50.054 red #10-32 UNF studs female (-) ground not applicable not applicable 591010
06.50.055 blue #10-32 UNF studs female (-) ground not applicable not applicable 501061
06.50.103 black #10-32 UNF studs male (-) ground not applicable not applicable 591040
31
IGNITION COILS
Non CSA Certified Ignition Coils – Standard Versions – For CATERPILLAR® G3400 & G3500 Series Gas Engines (Non CSA Applications)
P/N Color Primary Termination HV Termination Polarity ASC MOST Equivalent to
06.50.143 white DEUTSCH® connector female (-) ground not applicable not applicable 232-6352, 213-7443
06.50.147 1)
white DEUTSCH connector
®
female (-) ground not applicable x 232-6352, 213-7443
06.50.151 white DEUTSCH® connector female (-) ground not applicable not applicable 232-6346, 165-1589, 124-0749
06.50.1551) white DEUTSCH® connector female (-) ground not applicable x 232-6346, 165-1589, 124-0749
06.50.1571) white DEUTSCH® connector female (-) ground not applicable x 232-6350
1)
Ignition coils only for use with MIC4 and MIC5 ignition controllers.
Non CSA Certified Ignition Coils – Standard Versions – For CATERPILLAR® G3400 & G3500 Series Gas Engines (CSA Applications)
P/N Color Primary Termination HV Termination Polarity ASC MOST Equivalent to
06.50.1461) white DEUTSCH® connector female (-) ground not applicable x 232-6349, 165-1592, 122-8070
06.50.1481) white DEUTSCH® connector female (-) ground not applicable x 232-6353, 213-7444
06.50.1561) white DEUTSCH® connector female (-) ground not applicable x 232-6347, 165-1590
06.50.1581) white DEUTSCH® connector female (-) ground not applicable x 259-2078
1)
Ignition coils only for use with MIC4 and MIC5 ignition controllers.
32
Non CSA Certified Ignition Coils
Standard Versions – For CATERPILLAR® G3520C & G3600 Series & Perkins 4016-E61TRS Gas Engines
P/N Color Primary Termination HV Termination Polarity ASC MOST Equivalent to
06.50.1621) white DEUTSCH® connector female (-) ground not applicable x 310-3180
SYSTEMS
IGNITION
Non CSA Certified Ignition Coils – Accessories
– Repair Kits for MOTORTECH Ignition Coils1) – For CATERPILLAR® G3400 and G3500 Series Gas Engines
P/N Description Fits Ignition Coil P/N Extension Length Extension Diameter
NEW
with fastening material, spark plug extension
1)
For primary lead options, please refer to page 79, 81.
33
IGNITION COILS
Non CSA Certified Ignition Coils – Accessories – Boots for MOTORTECH Ignition Coils
Ignition Coil Side Outlet Ignition Coil 06.50. ...
P/N Figure Primary Secondary 90 ° 180 ° 003 053 054 055 060 100 102 103 104 105
06.80.037 1 x x x x x x x
06.84.082 2 x x x x x x
06.84.021 3 x x x1)
06.80.005 4 x x x x x x x
06.84.083 5 x x x x
06.80.006 6 x x x x
06.84.006 7 x x x x x x x
1)
Two boots needed for each ignition coil.
1 2 3 4 5 6 7
Non CSA Certified Ignition Coils – Accessories – Boots for ALTRONIC® Ignition Coils
Outlet
1 2
34
Non CSA Certified Ignition Coils – Accessories – Secondary Connections
Ignition Coil 06.50. ...
P/N Figure Description 003 053 054 055 060 100 102 103 104 105
SYSTEMS
IGNITION
06.84.025 8 Coil terminal, 180°, including terminal P/N 02.85.920 x
1 2 3 4 5 6 7 8 9
P/N Figure Description 003 053 054 055 060 100 102 103 104 105
1 2 3
35
IGNITION COILS
591012/
06.50.034 red MIL Style 3 pole pin female (-) ground not applicable not applicable
69694F
591018/
06.50.035 blue MIL Style 3 pole pin female (-) ground not applicable not applicable
(A)69694G
95.09.133 silver MIL Style 3 pole pin female (+) ground not applicable not applicable
591012/
95.09.134 silver MIL Style 3 pole pin female (-) ground not applicable not applicable
69694F
591018/
95.09.135 silver MIL Style 3 pole pin female (-) ground not applicable not applicable
(A)69694G
36
NEW
CSA Certified Ignition Coils – Flange Versions with Diagnostic Interface
MOTORTECH flanged ignition coils with diagnostic interface are
designed for operators who want to monitor their high voltage
traces in a simple way. Measuring high voltage peak (kV) and
spark duration (μsec) of all cylinders of an engine with flange
coils regularly, will allow easy maintenance of the equipment.
With a Scope Meter or the new MOTORTECH SparkView the
operator can receive real time data.
SYSTEMS
IGNITION
95.09.153 silver MIL Style 3 pole pin female (+) ground not applicable not applicable
95.09.1541) silver MIL Style 3 pole pin female (-) ground not applicable not applicable
95.09.1552) silver MIL Style 3 pole pin female (-) ground not applicable not applicable
1)
Same coil winding as P/N 06.50.034 / 95.09.134, but with diagnostic interface. Thus also equivalent to P/N 591012 and 69694F.
2)
Same coil winding as P/N 06.50.035 / 95.09.135, but with diagnostic interface. Thus also equivalent to P/N 591018 and 69694G / A69694G.
3)
Use of ignition coil only possible, if conversion kits P/N 75.30.143 or 75.30.144 previously were used.
37
IGNITION COILS
SHIELDED
CSA Certified Ignition Coils – Externally Mounted
Shielded – externally mounted – ignition coils are encapsu-
lated in a steel housing with welded lids. A bracket is used to
install the coils on a wiring rail or directly on the engine. This
type of ignition coil is connected to the shielded spark plug by
a braided high tension lead with a 3/4 in. or 1 in. termination.
Primary voltage connection is made by a 2 or 3 pole military
style screw connector. All parts meet the CSA Class I, Division
2, Group C/D.
95.09.005 silver MIL Style 3 pole pin 3/4-20 UNEF (-) ground x x
291001-S/
95.09.053 95.09.001 silver MIL Style 3 pole pin 3/4-20 UNEF (+) ground not applicable not applicable
10-382080
95.09.054 95.09.003 silver MIL Style 3 pole pin 3/4-20 UNEF (-) ground not applicable not applicable 591010-S
95.09.055 95.09.002 silver MIL Style 3 pole pin 3/4-20 UNEF (-) ground not applicable not applicable 501061-S
38
CSA Certified Ignition Coils – Integral Standard Versions
Integral ignition coils are designed to be mounted directly on
a dual threaded spark plug. No spark plug lead is required.
These ignition coils are mostly used in hazardous applica-
tions. Coil life is effected by the temperature that is transfer-
red into the coil by the spark plug. On occasions where the
spark plug leaks high combustion pressure enters the ignition
coil and forces the base coil to blow out of it`s housing.
MOTORTECH has designed a top cover safety ring that will not
allow this to happen. Also, the actual coil is located in upper
end of the coil housing and is effected less by the temperature
(cooler location).
CSA Certified Ignition Coils – Integral Standard Versions – 3 Pole Primary Connector Arrangement – ALTRONIC® Compatible
HV Termination
SYSTEMS
IGNITION
P/N Supersedes Color Length Primary Termination Outer Thread Inner Thread Polarity ASC MOST Equivalent to
1-20 13/16-20
95.09.030 95.09.010 silver 5.82 in. MIL Style 3 pole pin (-) ground not applicable not applicable 591007
UNEF UNEF
1-20 13/16-20
95.09.031 95.09.011 silver 5.82 in. MIL Style 3 pole pin (+) ground not applicable not applicable 591008
UNEF UNEF
13/16-20
95.09.040-6 95.09.012-6 silver 5.78 in. MIL Style 3 pole pin (-) ground not applicable not applicable 591011A
UNEF
13/16-20
95.09.040-10 95.09.012-10 silver 10.15 in. MIL Style 3 pole pin (-) ground not applicable not applicable
UNEF
13/16-20 591011B/
95.09.040-12 95.09.012-12 silver 12.15 in. MIL Style 3 pole pin (-) ground not applicable not applicable
UNEF 591011C
CSA Certified Ignition Coils – Integral Standard Versions – 2 Pole Primary Connector Arrangement
HV Termination
P/N Supersedes Color Length Primary Termination Outer Thread Inner Thread Polarity ASC MOST Equivalent to
1-20 13/16-20
95.08.030-6 95.08.010-6 silver 5.78 in. MIL Style 2 pole pin (-) ground not applicable not applicable PPT2477AA6
UNEF UNEF
13/16-20
95.08.030-8 95.08.010-8 silver 8.15 in. MIL Style 2 pole pin (-) ground not applicable not applicable PPT2477AA8
UNEF
13/16-20
95.08.030-10 95.08.010-10 silver 10.15 in. MIL Style 2 pole pin (-) ground not applicable not applicable PPT2477AA10
UNEF
13/16-20
95.08.030-12 95.08.010-12 silver 12.15 in. MIL Style 2 pole pin (-) ground not applicable not applicable PPT2477AA12
UNEF
39
IGNITION COILS
CSA Certified Ignition Coils – Integral High Energy Versions – 3 Pole Primary Connector Arrangement
HV Termination
P/N Supersedes Color Length Primary Termination Outer Thread Inner Thread Polarity ASC MOST Equivalent to
13/16-20
95.09.050-6 95.09.013-6 silver 5.50 in. MIL Style 3 pole pin 1-20 UNEF (-) ground x x
UNEF
13/16-20
95.09.060-111) silver 11.00 in. MIL Style 3 pole pin (-) ground x x
UNEF
95.09.013-12/ 13/16-20
95.09.060-12 silver 12.00 in. MIL Style 3 pole pin (-) ground x x
95.09.021-12 UNEF
13/16-20
95.09.060-14.5 95.09.021-14.5 silver 14.50 in. MIL Style 3 pole pin (-) ground x x
UNEF
1)
For use on WAUKESHA® VHP-GSI with rain shield.
CSA Certified Ignition Coils – Integral High Energy Versions – 3 Pole Primary Connector Arrangement – ALTRONIC® Compatible
For existing installations with ALTRONIC® ignition controllers, are designed to have the electrical characteristics to function
MOTORTECH offers a special series of high energy integral with the ALTRONIC® patented “Spark Reference“ high voltage
ignition coils with 3-pin primary connector. The ignition coils indication system.
CSA Certified Ignition Coils – Integral High Energy Versions – 3 Pole Primary Connector Arrangement – ALTRONIC® Compatible
HV Termination
P/N Supersedes Color Length Primary Termination Outer Thread Inner Thread Polarity ASC MOST Equivalent to
13/16-20
95.09.051-6 silver 5.50 in. MIL Style 3 pole pin 1-20 UNEF (-) ground not applicable not applicable
UNEF
13/16-20
95.09.061-111) silver 11.00 in. MIL Style 3 pole pin (-) ground not applicable not applicable
UNEF
13/16-20
95.09.061-12 silver 12.00 in. MIL Style 3 pole pin (-) ground not applicable not applicable
UNEF
13/16-20
95.09.061-14.5 silver 14.50 in. MIL Style 3 pole pin (-) ground not applicable not applicable
UNEF
1)
For use on WAUKESHA® VHP-GSI with rain shield.
40
CSA Certified Ignition Coils – Integral High Energy Versions – 2 Pole Primary Connector Arrangement
MOTORTECH high energy integral ignition coils are also MOTORTECH MIC500, MIC850, MIC4 and MIC5 (includes sup-
available with 2-pole primary connector for use with port of ASC and MOST feature) series ignition controllers.
CSA Certified Ignition Coils – Integral High Energy Version – 2 Pin Primary Connector Arrangement
HV Termination
P/N Supersedes Color Length Primary Termination Outer Thread Inner Thread Polarity ASC MOST Equivalent to
13/16-20
95.08.040-6 95.08.020-6 silver 5.50 in. MIL Style 2 pole pin 1-20 UNEF (-) ground x x PPT2477AB6
UNEF
13/16-20
95.08.050-111) silver 11.00 in. MIL Style 2 pole pin (-) ground x x
UNEF
95.08.020-12/ 13/16-20
95.08.050-12 silver 12.00 in. MIL Style 2 pole pin (-) ground x x PPT2477AB12
95.08.021-12 UNEF
13/16-20
95.08.050-14.5 95.08.021-14.5 silver 14.50 in. MIL Style 2 pole pin (-) ground x x
UNEF
SYSTEMS
IGNITION
1)
For use on WAUKESHA® VHP-GSI with rain shield.
CSA Certified Ignition Coils – Integral Standard and High Energy Versions – Accessories – Teflon Grommets
P/N Description Integral Ignition Coil Type Engine Make and Model
06.84.069 Teflon grommet standard / high energy WAUKESHA® VHP and VGF series
41
42
TRIGGERING
Any Electronic Ignition System requires signals from the Crankshaft and/or from the Camshaft. These events are
sensed by teeth, pins or holes on the flywheel and magnets or holes on the camshaft.
The generated signal will be used by the ignition controller to calculate the position of the camshaft, crankshaft as
well as the speed of the rotating equipment.
43
TRIGGERING
D
NON-SHIELDE
Pickups
A wide range of special ignition pickups are available from High Quality, designed to meet the application and tempera-
MOTORTECH to allow service companies and operators to ture requirements, MOTORTECH Pickups will last and ensure
select what they need to do a professional installation. you are not experiencing any unexpected shut downs.
66.60.001-125 1 06.60.101 5/8-18 UNF 1.25 in. Holes, Pins, Teeth, Screws
66.60.001-175 1 06.60.105 5/8-18 UNF 1.75 in. Holes, Pins, Teeth, Screws 691118-1
66.60.001-250 1 06.60.102 5/8-18 UNF 2.50 in. Holes, Pins, Teeth, Screws 691118-2
66.60.001-400 1 06.60.103 5/8-18 UNF 4.00 in. Holes, Pins, Teeth, Screws 691118-4
66.60.001-600 1 06.60.107 5/8-18 UNF 6.00 in. Holes, Pins, Teeth, Screws 691118-6
NEW
Non CSA Certified Magnetic Pickups – Thread Size 3/4-16 UNF
P/N Figure Supersedes Thread Size Thread Length Trigger Equivalent to
66.60.011-180 2 3/4-16 UNF 1.80 in. Holes, Pins, Teeth, Screws 791015-1
Non CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active Low
P/N Figure Supersedes Thread Size Thread Length Trigger Equivalent to
44
Non CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active High1)
P/N Figure Supersedes Thread Size Thread Length Trigger Equivalent to
SYSTEMS
IGNITION
Legend
1 2 3 4
45
TRIGGERING
SHIELDED
CSA Certified Magnetic Pickups – Thread Size 5/8-18 UNF
P/N Figure Supersedes Thread Size Thread Length Trigger Equivalent to
95.70.001-175 1 5/8-18 UNF 1.75 in. Holes, Pins, Teeth, Screws 691118-1
95.70.001-250 1 5/8-18 UNF 2.50 in. Holes, Pins, Teeth, Screws 691118-2
95.70.001-400 1 5/8-18 UNF 4.00 in. Holes, Pins, Teeth, Screws 691118-4
95.70.001-600 1 5/8-18 UNF 6.00 in. Holes, Pins, Teeth, Screws 691118-6
CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active Low
P/N Figure Supersedes Thread Size Thread Length Trigger Equivalent to
CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active High1)
P/N Figure Supersedes Thread Size Thread Length Trigger Equivalent to
Legend
1 2 3 4
46
Pickup Leads
The reliability of an electronic ignition system comes with its a 90° Connector is used as it routes the wire downwards and
accessories. Every Pickup needs a lead to connect to the igni- puts less side load stress on the pickup.
tion controller and ensure that the signal is transmitted wit- There are two lines of pickup leads available
hout any malfunctions. MOTORTECH offers high grade pickup • NON shielded standard versions
leads that are all shielded against RFI interference. Preferably • Braided versions which meet CSA Class I; Division2; Group C
SYSTEMS
IGNITION
06.71.002-L 2 3 pole socket, 90° "L"= 5/15/25/50 ft.
95.60.010-L 4 2 pole socket, 180° "L"= 12/24/48/72/96 in. 1/2-14 NPT 593048-L
95.60.020-L 4 2 pole socket, 90° "L"= 12/24/48/72/96 in. 1/2-14 NPT 593054-L
1)
Other lengths available on request.
95.60.030-L 5 3 pole socket, 180° "L"= 12/24/48/72/96 in. 1/2-14 NPT 593052-L
95.60.040-L 5 3 pole socket, 90° "L"= 12/24/48/72/96 in. 1/2-14 NPT 593057-L
1)
Other lengths available on request.
1 2 3 4 5 6
47
TRIGGERING
TriDev
MOTORTECH TRIGGERING DEVICES
A = Gear Ratio
1 = 1:1
2 = 2:1
Trigger Devices 3 = 3:1
For applications where a trigger disc 6 = 1.5:1
can not be mounted due to difficult
camshaft access, a trigger device is B = Rotation
available. This unit is mounted at the 1 = CW (clockwise)
location where the ignition magneto
2 = CCW (counterclockwise)
was installed. A built in trigger disc will
sense the events necessary to trigger
the ignition control unit. One (1) to a C = Trigger Arrangement
maximum of eight (8) trigger events are 1 = 1 only - Pin
possible. 2 = 2+1 - Pin
48
Trigger Conversion Kits for CATERPILLAR® G3300 & G3400 Series
P/N Figure Supersedes Description Events
Accessories for Trigger Conversion Kits for CATERPILLAR® G3300 & G3400 Series
P/N Figure Supersedes Description Engine
SYSTEMS
IGNITION
P/N Figure Supersedes Description Events
06.24.009 1)
2 Trigger device for CATERPILLAR G379/G398/G399
®
1)
Pickup and lead have to be ordered separately.
75.30.137 1)
3 Trigger conversion kit for DOOSAN GV222TI
®
1)
Pickup and lead have to be ordered separately. Illustration shows mounted kit on camshaft gear.
06.22.400-6 4 Trigger device for WHITE SUPERIOR® Model G825 / GT825 6+1
1a
1 2 3 4 5 6
49
TRIGGERING
Trigger Discs
A large variety of different trigger discs is available to support mechanical driven magneto ignition. Select between univer-
upgrades performed by installing new electronic ignition sal trigger discs with magnets, metal inlets or discs that are
systems on engines that used to be equipped with specially designed for particular engine models.
50
Trigger Discs with Metal Inlets
P/N Figure Supersedes Description Diameter Events Equivalent to
06.20.400 1 Trigger disc with metal inlets 7.45 in. 2+1 790302-1
06.20.401 1 Trigger disc with metal inlets 7.45 in. 3+1 790303-1
06.20.402 1 Trigger disc with metal inlets 5.00 in. 4+1 790314-1
06.20.403 1 Trigger disc with metal inlets 5.00 in. 6+1 790316-1
06.20.404 1 Trigger disc with metal inlets 5.00 in. 8+1 790318-1
06.20.069-6 2 Trigger disc with magnets WAUKESHA® VHP series - 6 cylinders 7.45 in. 6+1 305805R
SYSTEMS
IGNITION
06.20.069-1 2 Trigger disc with magnet WAUKESHA® VHP series 7.45 in. 1
06.20.252 3 Trigger disc with magnets WAUKESHA® VHP series - 16 cylinders 5.35 in. 8+1 305805N
06.20.254 3 Trigger disc with magnet WAUKESHA® VHP series 5.35 in. 1
06.20.0251) 3 Trigger disc with magnets WAUKESHA® VHP series - 6 cylinders 7.45 in. 6+1 305805F
06.20.026 1)
3 06.20.025-1 Trigger disc with magnets WAUKESHA VHP series - 12 cylinders
®
7.45 in. 12+1 305805G
06.20.026-11) 3 Trigger disc with magnet WAUKESHA® VHP series 7.45 in. 1
06.20.045-6 3 Trigger disc with magnets WAUKESHA® VGF series - 6 cylinders 5.00 in. 6+1 305805
06.20.045-8 3 Trigger disc with magnets WAUKESHA® VGF series - 8 cylinders 5.00 in. 8+1 305805A
1 2 3 4 5
51
TRIGGERING
Trigger Magnets
P/N Figure Supersedes Description Thread Length Equivalent to
1 2 3
52
NOTES
IGNITION
53
SYSTEMS
54
HIGH TENSION LEADS AND ACCESSORIES
Since the mid of the 90‘s, MOTORTECH has become one of the leading manufacturers of unshielded and shielded
high tension leads (spark plug leads). The PolyMotTM design, which was patented in 1996, has created a big
change in the industry to more reliable equipment that is capable to transfer high voltages from the ignition coil to
the spark plug. Increasing load demand, higher efficiencies and lean burn operation coupled to the use of alterna-
tive gas qualities like bio gases have made it mandatory to have a good terminal connection to the coil as well as
to the spark plug. A built in suppression resistor reduces the RFI noise that can be critical when electronic ignition
is used and extra electrical spikes are recognized as pickup signal.
In the industry where Class I; Div 2 certification is required, MOTORTECH today offers the MOT-Blues
MotBlues ––aashielded
shieldedand
CSA CSA
and approved
approved
highhigh
tension
tension
leadlead
– which
– which
doesdoes
not have
not have
the poor
the poor
performance
performance
as the
asstandard
the standard
shielded
shielded
designs.
de-
The MotBlues
signs. The MOT-Blues
has been
has
accepted
been accepted
very wellvery
by the
wellbig
by integral
the big integral
compressor
compressor
engine market.
engine market.
55
HIGH TENSION LEADS AND ACCESSORIES
PolyMot™
MOTORTECH SPARK PLUG LEADS & EXTENSIONS
Ceramic Insert
with 5 kΩ resistor
Silicone Seal
Features:
The unique structure has achieved tremendous reliability records in the field.
• Rigid design
• TEFLON extension up to 36 in. length
• 5 kΩ built in ceramic insert
• Reliable coil and spark plug terminal
• The blue silicone spark plug wire is specially designed and has a dielectric
strength of 68 kV
• Critical high voltage areas are protected with a silicone seal against
water and dirt
• Designed to match the engine model, the spark plug type and application
• Leads are labeled with P/N and production code for easy traceability
• Comes with 2 years warranty
Comparison between OEM part (slim) Perfect fit Water flood test
and MOTORTECH PolyMotTM
56
High Tension Lead Specification Chart
SYSTEMS
IGNITION
Please consult factory or your nearest MOTORTECH distributor to get the correct PolyMotTM high tension lead, specified for your
engine application. Questionnaire for PolyMotTM specification.
A Length of insulator
F Length of wire
G Type of coil
Terminal to coil
57
HIGH TENSION LEADS AND ACCESSORIES
Popular Spark P/N Silicone Extension Lead Output Wire Ignition Coil
P/N Engine Make Model Resistance2)
Length1) Plug Seal Ring Length fromExtension Length Connection
06.85.908-L AJAX® 2802 L=22 in. 3076 06.84.059 6 in. 6 kΩ 180° 17 in. 6
06.85.751-L CATERPILLAR® G3400 series L=18 in. GE3-5 06.84.059 13 in. 5 kΩ 90° 18 in. 1
06.85.939-L CATERPILLAR ®
G3400 series L=18 in. GE3-5 06.84.059 13 in. 5 kΩ 90° 18 in. 5a
06.85.594-L CATERPILLAR® G3500 series L=16 in. GI3-1 06.84.040 15 in. 5 kΩ 90° 16 in. 1
06.85.954-L CATERPILLAR ®
G3500 series L=16 in. GI3-1 06.84.040 15 in. 6 kΩ 90° 16 in. 6
06.85.505-L CLARK® TLA-6 L=18 in. RW80N 06.84.040 11 in. 5 kΩ 90° 18 in. 5a
06.85.966-L CLARK® TCV-16 L=35 in. GK3-5 06.84.044 11 in. 5 kΩ 180° 24 in. 5a
06.85.670-L COOPER® GMV-8 L=12 in. RW77PP 06.84.040 11 in. 5 kΩ 90° 12 in. 5a
06.85.910-L COOPER ®
LSV-16 (Middle of Head) L=18 in. RW80PP 06.84.040 22 in. 5 kΩ 90° 18 in. 1
06.85.909-L COOPER ®
LSV-16 (Side of Head) L=24 in. RW80PP 06.84.040 14 in. 5 kΩ 90° 24 in. 1
06.85.083-L CUMMINS® 5.9 / GTA 8.3 L=22 in. GK3-5 06.84.033 6 in. 5 kΩ 180° 16 in. 4
06.85.683-L CUMMINS ®
G855 L=18 in. GK3-5 06.84.044 12 in. 5 kΩ 90° 18 in. 1
06.85.947-L CUMMINS® QSK60G L=8 in. GI3-5 06.84.040 15 in. 5 kΩ 90° 8 in. 1
06.85.946-L CUMMINS ®
QSV81G/QSV91G L=8 in. GI3-5 06.84.040 17 in. 5 kΩ 90° 8 in. 1
06.85.320H-L DEUTZ®/MWM® 234 series L=18 in. GE3-5 06.84.059 6 in. 5 kΩ 90° 18 in. 1
06.85.179-L DEUTZ®/MWM® 620 series L=20 in. GL3-3 06.84.040 10 in. 5 kΩ 90° 20 in. 1
06.85.926-L IVECO® GE8291SRG75 L=20 in. GK3-5 06.84.044 10 in. 5 kΩ 90° 20 in. 1
06.85.487-L LIEBHERR ®
G924 / G926 L=18 in. GK3-5 06.84.033 6 in. 5 kΩ 180° 12 in. 2
06.85.873-L LIEBHERR ®
G926TI L=18 in. GK3-5 06.84.033 6 in. 5 kΩ 180° 12 in. 7
06.85.709H-L MAN ®
E0834E/LE / E0836E L=16 in. GK3-5 06.84.044 6 in. 5 kΩ 180° 10 in. 1
06.85.989-L MAN ®
E0834E/LE / E0836E L=16 in. GE3-5 06.84.059 6 in. 5 kΩ 180° 10 in. 1a
06.85.577H-L MAN® E0834E/LE / E0836E L=16 in. GK3-5 06.84.044 6 in. 5 kΩ 180° 10 in. 2
06.85.879-L MAN ®
E0834E/LE / E0836E L=16 in. GK3-5 06.84.044 6 in. 5 kΩ 180° 11 in. 4
06.85.717H-L MAN® E0834E/LE / E0836E L=24 in. GK3-5 06.84.044 6 in. 6 kΩ 180° 18 in. 6
06.85.839H-L MAN ®
E0834E/LE / E0836E L=16 in. GK3-5 06.84.044 6 in. 5 kΩ 180° 10 in. 7
06.85.580H-L MAN® E0836LE / E28 series L=18 in. GE3-5 06.84.059 6 in. 5 kΩ 180° 12 in. 1
06.85.988-L MAN ®
E0836LE / E28 series L=16 in. GK3-5 06.84.044 6 in. 5 kΩ 180° 10 in. 1a
06.85.415H-L MAN® E0836LE / E28 series L=16 in. GE3-5 06.84.059 6 in. 5 kΩ 180° 10 in. 2
06.85.836H-L MAN ®
E0836LE / E28 series L=16 in. GE3-5 06.84.059 6 in. 5 kΩ 180° 10 in. 7
06.85.929-L MAN® E2676LE202 L=20 in. GK3-5 06.84.044 11 in. 5 kΩ 180° 10 in. 7
06.85.959-L MAN ®
E3262LE202 L=22 in. GE3-5 06.84.059 10 in. 5 kΩ 180° 13 in. 7
06.85.271 WÄRTSILÄ ®
25SG series GE3-5 06.84.059 17 in. 5 kΩ 90° 14 in. 4
06.85.948-L WÄRTSILÄ ®
28SG series L=8 in. GI3-5 06.84.040 21 in. 5 kΩ 90° 8 in. 1
06.85.306-L WAUKESHA ®
VGF series L=18 in. GI3-1 06.84.040 12 in. 5 kΩ 90° 18 in. 1
06.85.326-L WAUKESHA® VGF series L=16 in. GI3-1 06.84.040 10 in. 5 kΩ 180° 6 in. 1
06.85.429-L WAUKESHA ®
VGF series L=14 in. GI3-1 06.84.040 11 in. 5 kΩ 90° 14 in. 1
06.85.423-L WAUKESHA ®
VHP GL series L=16 in. GT3-1 06.84.040 11 in. 5 kΩ 90° 16 in. 1
1)
"-L" can be any length from 8 in. to 36 in. in 2 in. increments. For loose connector and 36 in. length add "-K" to part number (e.g. 06.85.908-K)
58 2)
For 0 kΩ resistance, please add "-0" to part number (e.g. 06.85.908-22-0).
PolyMot High Tension Leads – for common Applications
Popular Spark P/N Silicone Extension Lead Output Wire Ignition Coil
P/N Engine Make Model Resistance2)
Length1) Plug Seal Ring Length fromExtension Length Connection
06.85.739-L WAUKESHA® VHP GL series L=16 in. GT3-1 06.84.040 9 in. 5 kΩ 90° 16 in. 1
06.85.649-L WAUKESHA® VHP GL series L=24 in. GT3-1 06.84.040 11 in. 5 kΩ 90° 24 in. 5a
06.85.945-L WAUKESHA® VHP GL series L=16 in. GT3-1 06.84.040 9 in. 6 kΩ 90° 16 in. 6
06.85.422-L WAUKESHA® VHP GU series L=16 in. GT3-1 06.84.040 13 in. 5 kΩ 90° 16 in. 1
06.85.688-L WAUKESHA ®
VHP GU series L=16 in. GI3-1 06.84.040 11 in. 5 kΩ 90° 16 in. 1
06.85.699-L WAUKESHA® VHP GU/GSI series L=16 in. M82N 06.84.040 12 in. 5 kΩ 90° 16 in. 1
06.85.705-L WAUKESHA ®
VHP GU/GSI series L=16 in. GT3-1 06.84.040 12 in. 5 kΩ 90° 16 in. 1
06.85.720-L WAUKESHA® VHP GU/GSI series L=18 in. GT3-1 06.84.040 12 in. 5 kΩ 90° 18 in. 1
06.85.672H-L WAUKESHA ®
VHP GU/GSI series L=22 in. GI3-1 06.84.040 14 in. 5 kΩ 90° 22 in. 5a
06.85.894-L WAUKESHA ®
VHP GU/GSI series L=18 in. GT3-1 06.84.040 14 in. 6 kΩ 90° 18 in. 6
SYSTEMS
IGNITION
06.85.714-L WAUKESHA ®
VHP/AT series L=24 in. GI3-1 06.84.040 18 in. 5 kΩ 90° 24 in. 1
06.85.678-L WAUKESHA ®
VSG series L=24 in. GE3-5 06.84.059 5 in. 5 kΩ 180° 18 in. 1
06.85.667-L WHITE SUPERIOR® G825 series L=24 in. GT3-1 06.84.040 8 in. 5 kΩ 90° 24 in. 1
1 1a 2 3 4 5* 6 7 8 9 10
PolyMot High Tension Leads − Flange Kit for High Tension Leads for WAUKESHA® VHP / AT and CATERPILLAR® G3500 Series
P/N Description
06.51.248 Flange kit for use with P/N 06.85.714-L, P/N 06.85.594-L and P/N 06.85.954-L
GE3-5 /
06.88.009-L3) 06.88.008-L/-K G3300 series L=16 in. 06.84.059 3.75 in. 0 kΩ 180° 12 in. 1
GN3-1
06.88.010-L G3300 series L=16 in. GE3-5 06.84.059 4.25 in. 0 kΩ 180° 12 in. 2
06.88.003-L/-K
06.85.751-L4) G3400 series L=18 in. GE3-5 06.84.059 13.00 in. 5 kΩ 90° 18 in. 1
06.85.687-L
06.85.939-L G3400 series L=18 in. GE3-5 06.84.059 13.00 in. 5 kΩ 90° 18 in. 5a
06.88.004-L G342/G379/G398/G399 L=20 in. GE3-5 06.84.059 4.25 in. 0 kΩ 180° 16 in. 2
06.88.005-L G342/G379/G398/G399 L=20 in. GN3-1 06.84.044 4.25 in. 0 kΩ 180° 16 in. 3
06.88.006-L 06.88.001-L/-K G342/G379/G398/G399 L=20 in. GE3-5 06.84.059 4.25 in. 0 kΩ 180° 16 in. 1
06.88.007-L 06.88.002-L/-K G342/G379/G398/G399 L=20 in. GI3-1 06.84.040 3.70 in. 0 kΩ 180° 16 in. 1
06.88.011-L G342/G379/G398/G399 L=20 in. GE3-5 06.84.059 4.25 in. 0 kΩ 180° 16 in. 9
06.85.674-L G342/G379/G398/G399 L=16 in. GT3-1 06.84.040 5.00 in. 0 kΩ 90° 16 in. 9
1)
"-L" can be any length from 8 in. to 36 in. in 2 in. increments. For loose connector and 36 in. length add "-K" to part number (e.g. 06.85.751-K)
2)
For 0 kΩ resistance, please add "-0" to part number (e.g. 06.85.939-18-0).
3)
P/N 06.88.009-16 equivalent to P/N 7W2479.
4)
P/N 06.85.751-18 equivalent to P/N 7W8542 / 2624855 / 2502149.
06.85.697-L AJAX® 230 L=20 in. GT3-1 06.84.040 5 in. 0 kΩ 90° 20 in. 1
06.85.698-L AJAX ®
230 L=30 in. GT3-1 06.84.040 5 in. 0 kΩ 90° 30 in. 5a
06.85.719-L AJAX® 230 L=16 in. W18 06.81.017 5 in. 0 kΩ 90° 16 in. 1
06.85.773-L AJAX ®
230 L=15 in. GT3-1 06.84.034 5 in. 0 kΩ 90° 15 in. 5a
06.85.860-L ARROW® VRG176/VRG220/VRG330 L=14 in. J6C / J8C 06.84.059 5 in. 1 kΩ 90° 14 in. 6
06.85.514-L CLARK ®
TLA-6 L=16 in. RW80N 06.84.038 8 in. 0 kΩ 90° 16 in. 5a
06.85.903-L3) CUMMINS® GTA 8.3 L=22 in. GK3-5 5 in. 5 kΩ 180° 17 in. 8
06.85.949-L DEUTZ ®
2015 series L=10 in. 14GZ6-77-2 06.84.033 9 in. 6 kΩ 90° 10 in. 6
06.85.953-L DOOSAN® GV222TIC L=10 in. GK3-5 06.81.071 12 in. 5 kΩ 90° 10 in. 1
06.85.964-L LIEBHERR® G9408 L=20 in. GK3-5 06.81.071 6 in. 5 kΩ 180° 14 in. 2
1 1a 2 3 4 5* 6 7 8 9 10
60
Unshielded Safety Leads for Shielded Spark Plugs
09.02.1000-L 2.125 in. 180° 180° 291001-S, 501061-S, 591010-S USL2A-"L"A / AWH81-"L"
SYSTEMS
IGNITION
09.02.1210-L 2.125 in. 180° 90° x 291001-S, 501061-S, 591010-S RSL2AL-"L"A
61
HIGH TENSION LEADS AND ACCESSORIES
09.02.4000-L 2.125 in. 180° 180° 291001, 501061, 591010 USL2E-"L"A / AWH72-"L"
09.02.4110-L 2.125 in. 180° 180° x 291001, 501061, 591010 USL2E-"L"A w. 06.80.030
09.02.7000-L 2.125 in. 180° 180° Unshielded in Coil Box inst. USL2G-"L"A /AWH62-"L"
09.02.7001-L 2.125 in. 90° 180° Unshielded in Coil Box inst. USL2LG-"L"A
09.02.7100-L 2.125 in. 180° 180° x Unshielded in Coil Box inst. USL2G-"L"AIPS
09.02.7101-L 2.125 in. 90° 180° x Unshielded in Coil Box inst. USL2LG-"L"AIPS
09.02.7200-L 2.125 in. 180° 180° x Unshielded in Coil Box inst. RSL2G-"L"A
09.02.7201-L 2.125 in. 90° 180° x Unshielded in Coil Box inst. RSL2LG-"L"A
09.02.7300-L 2.125 in. 180° 180° x x Unshielded in Coil Box inst. RSL2G-"L"AIPS
09.02.7301-L 2.125 in. 90° 180° x x Unshielded in Coil Box inst. RSL2-LG-"L"AIPS
1)
"-L" can be any lead length from 8 in. to 36 in. in 2 in. increments.
62
Unshielded Safety Leads for Conventional Spark Plugs
SYSTEMS
IGNITION
09.08.1000-L 0.470 in. 180° 180° 291001-S, 501061-S, 591010-S USLA51SPB-"L"A
63
HIGH TENSION LEADS AND ACCESSORIES
02.85.757 1 Ignition cable, 7 mm silicone, 100 ft. spool, dielectric strength 68 kV, 17-19 stends blue
02.85.758 2 Ignition cable, 7 mm silicone, 100 ft. spool, dielectric strength 68 kV, 17-19 stends orange
02.85.658 2 Ignition cable, 7 mm silicone, 100 ft. spool, dielectric strength 68 kV, 17-19 stends orange
06.84.024-100 6 Spark plug terminal, 90°, silicone for use with 7 mm ignition cable, including terminal P/N 02.85.920 100 pcs.
06.84.025-100 7 Spark plug terminal, 180°, silicone for use with 7 mm ignition cable, including terminal P/N 02.85.920 100 pcs.
1 2 3 4 5 6 7
64
Accessories – Spark Plug Boots
P/N Figure Description Quantity
06.84.008-100 8 Spark plug boot, 90°, silicone for use with 7 mm ignition cable and terminal P/N 22.85.803 100 pcs.
06.84.009-100 9 Spark plug boot, 180°, silicone for use with 7 mm ignition cable and terminal P/N 22.85.802 100 pcs.
02.85.920-100 10 Terminal, for use with spark plug boot P/N 06.84.024 and P/N 06.84.025 100 pcs.
22.85.802-100 11 Terminal, for use with spark plug boot P/N 06.84.009 100 pcs.
22.85.803-100 12 Terminal, for use with spark plug boot P/N 06.84.008 100 pcs.
SYSTEMS
Accessories – Spark Plug Terminals
IGNITION
P/N Figure Description Equivalent to Quantity
02.85.924-100 13 Spark plug terminal, 90°, for use with 7 mm ignition cable T-22 100 pcs.
02.85.925-100 14 Spark plug terminal, 180°, for use with 7 mm ignition cable T-33 100 pcs.
06.80.030-100 15 Ignition coil terminal, 180°, 1 kΩ resistance, requires crimp terminal P/N 06.80.126 100 pcs.
22.80.009-100 16 Ignition coil terminal, 90°, 1 kΩ resistance, requires crimp terminal P/N 06.80.126 100 pcs.
06.80.091-1001) 17 Ignition coil terminal, 180°, 1 kΩ resistance, requires crimp terminal P/N 06.80.126 100 pcs.
1)
For ignition coils with positive secondary termination.
8 9 10 11 12 13 14 15 16 17
65
HIGH TENSION LEADS AND ACCESSORIES
06.80.012-100 1 Crimp terminal, 180°, for use with spreading adaptor P/N 02.85.1004 100 pcs.
06.80.116-100 2 Crimp terminal, 90°, for use with MOTORTECH style ignition coils 100 pcs.
06.80.116-180-100 3 Crimp terminal, 180°, for use with New MOTORTECH style ignition coils 100 pcs.
06.80.108-100 4 Crimp Terminal Base, for use with crimp terminals P/N 06.80.116-100 and P/N 06.80.116-180-100 100 pcs.
06.80.126-100 5 Crimp Terminal Base, for use ignition coil terminals P/N 06.80.030 and P/N 22.80.009 100 pcs.
1 2 3 4 5 6
66
Accessories – Distance Collars
P/N Figure Description Quantity
06.86.001-100 7 Distance collar, for use with 7 mm ignition cable 100 pcs.
06.86.002-100 8 Distance collar, for use with 7 mm ignition cable 100 pcs.
06.86.003-100 9 Distance collar, for use with 7 mm ignition cable 100 pcs.
06.86.005-100 10 Distance collar, for use with 7 mm ignition cable 100 pcs.
SYSTEMS
IGNITION
06.84.040-100 11 Silicone seal ring 14.6 x 2.7 mm 100 pcs.
06.84.048-100 12 Grommet, for use with CUMMINS ignition coil P/N 3930027
®
orange 100 pcs.
06.84.053-100 13 Grommet, for use with CUMMINS® 8.3 ignition coil black 100 pcs.
Accessories – Silicone Seals for ALTRONIC®, BG®, CUMMINS® and WAUKESHA® Spark Plug Extensions
P/N Figure Description Color Quantity
06.84.047-100 14 Silicone seal, for 14 mm spark plug extension orange 100 pcs.
06.84.049-100 15 Silicone seal, for 18 mm spark plug extension blue 100 pcs.
7 8 9 10 11 12 13 14 15
67
HIGH TENSION LEADS AND ACCESSORIES
68
SHIELDED
MOT-Blues Shielded High Tension Leads for Externally Mounted Ignition Coils – MOTORTECH Style
P/N1) Description Ignition Coil Termination Spark Plug Termination Spark Plug Terminal Well Depth2) Equivalent to
95.91.030-L Shielded high tension lead 1-20 UNEF / 180° 180° 2 in. A755-L-2 / HT2400-L
MOT-Blues Shielded High Tension Leads for Externally Mounted Ignition Coils – ALTRONIC® Style
P/N1) Description Ignition Coil Termination Spark Plug Termination Spark Plug Terminal Well Depth2) Equivalent to
95.90.030-L Shielded high tension lead 3/4-20 UNEF / 180° 180° 2 in. 593030-L / HT2300-L
MOT-Blues Shielded High Tension Leads for MOTORTECH Igniter Assy Ignition Coils
P/N1) Description Ignition Coil Termination Spark Plug Termination Spark Plug Terminal Well Depth2) Equivalent to
SYSTEMS
IGNITION
Standard lead lengths = "L" = 10 in., 13 in., 16 in., 18 in., 20 in., 24 in., 30 in.; other lengths available on request.
1)
Conventional Shielded High Tension Leads for Externally Mounted Ignition Coils – MOTORTECH Style
P/N1) Description Ignition Coil Termination Spark Plug Termination Spark Plug Terminal Well Depth2) Equivalent to
95.85.030-L Shielded high tension lead 1-20 UNEF / 180° 180° 2 in. A755-L-2 / HT2400-L
Conventional Shielded High Tension Leads for Externally Mounted Ignition Coils – ALTRONIC® Style
P/N1) Description Ignition Coil Termination Spark Plug Termination Spark Plug Terminal Well Depth2) Equivalent to
95.90.030-L Shielded high tension lead 3/4-20 UNEF / 180° 180° 2 in. 593030-L / HT2300-L
Conventional Shielded High Tension Leads for MOTORTECH Igniter Assy Ignition Coils
P/N1) Description Ignition Coil Termination Spark Plug Termination Spark Plug Terminal Well Depth2) Equivalent to
Standard lead lengths = "L" = 10 in., 13 in., 16 in., 18 in., 20 in., 24 in., 30 in.; other lengths available on request.
1)
-L
69
HIGH TENSION LEADS AND ACCESSORIES
02.85.1006 1 Terminal kit with stud thread size M3 3/4-20 UNEF, 2 in. terminal well depth
includes:
02.85.1007 2 Terminal kit with stud thread size M3 3/4-20 UNEF, ALTRONIC Style
®
includes:
02.85.929 Stud, M3
02.85.1008 3 Terminal kit with stud thread size M3 1-20 UNEF, MOTORTECH Style
includes:
02.85.611 Gasket
02.85.929 Stud, M3
1 2 3
70
Terminal Kits for Shielded High Tension Leads – Conventional (Metric)
P/N Figure Description Adaptor Spark Plug Equivalent to
02.85.991 1 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, 1 in. terminal well depth
includes:
02.85.956 Stud, M3
02.85.013 Spacer
SYSTEMS
IGNITION
P/N Figure Description Adaptor Spark Plug Equivalent to
02.85.991-2 2 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, 1 in. terminal well depth SC1K / 504205
includes:
02.85.013 Spacer
02.85.992 3 Terminal kit with stud thread size M3 3/4-20 UNEF, 2 in. terminal well depth
includes:
02.85.929 Stud M3
02.85.013 Spacer
1 2 3
71
HIGH TENSION LEADS AND ACCESSORIES
02.85.992-2 1 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, 2 in. terminal well SC2K / 504137
includes:
02.85.013 Spacer
02.85.979 2 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, 1 in. terminal well
includes:
02.85.954 Spring
02.85.992-1 3 Terminal kit with stud thread size M3 3/4-20 UNEF, BENDIX Style
®
includes:
02.85.929 Stud, M3
02.85.992-3 4 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, BENDIX® Style
includes:
02.85.013 Spacer
1 2 3 4
72
Terminal Kits for Shielded High Tension Leads – Conventional (Metric)
P/N Figure Description Adaptor Igniton Coil Equivalent to
02.85.996 1 Terminal kit with stud thread size M3 3/4-20 UNEF, ALTRONIC Style
®
includes:
02.85.929 Stud, M3
02.85.996-2 2 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, ALTRONIC Style
®
ALTSS-2
SYSTEMS
IGNITION
includes:
02.85.997 3 Terminal kit with stud thread size 3/48 UNC 1-20 UNEF, MOTORTECH Style
includes:
02.85.929 Stud, M3
06.81.059 O-ring
02.85.997-2 4 Terminal kit with stud thread size 3/48 UNC 1-20 UNEF, MOTORTECH Style
includes:
06.81.059 O-ring
1 2 3 4
73
HIGH TENSION LEADS AND ACCESSORIES
02.85.993 1 Terminal kit with stud thread size M3 3/4-20 UNEF, ALTRONIC Style
®
includes:
02.85.929 Stud, M3
02.85.993-2 2 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, ALTRONIC Style
®
ALTOS-1 / 510480
includes:
02.85.994 3 Terminal kit with stud thread size M3 3/4-20 UNEF, BENDIX® Style
includes:
02.85.929 Stud, M3
1 2 3
74
Terminal Kits for Non-Shielded High Tension Leads - Conventional (Imperial)
P/N Figure Description Adaptor Ignition Coil Equivalent to
02.85.994-2 1 Terminal kit with stud thread size 3/48 UNC 3/4-20 UNEF, BENDIX Style
®
BENDOS-1
includes:
SYSTEMS
IGNITION
P/N Figure Description Adaptor Ignition Coil Equivalent to
02.85.995 2 Terminal kit with stud thread size M3 1-20 UNEF, MOTORTECH Style
includes:
02.85.929 Stud, M3
02.85.611 Gasket
02.85.995-2 3 Terminal kit with stud thread size 3/48 UNC 1-20 UNEF, MOTORTECH Style FMOS-1
includes:
02.85.611 Gasket
1 2 3
75
76
PRIMARY LEADS
Shielded ignition systems require all wiring to be approved for hazardous locations. MOTORTECH manufactures a
wide
a wide
range
range
ofof
shielded
shielded
primary
primary
leads
leadsthat
that
meet
meetthe
the
CSA
CSA
Class
Class
I; I,Division2;
Division2,Group
GroupC/D;
D requirements.
T4 requirements.
A variety of leads is available to fit all common ignition coils and the MOTORTECH AlphaRail wiring rails. Heavy duty
connectors (non cadmium plated) and a thick stainless steel braid with hydraulic ends will make this product live
in a harsh environment.
77
PRIMARY LEADS
The new oil and UV resistant multi-conductor wire is specially designed for shielded CSA certified primary leads.
It consists of a multi layer design:
·Fine bare copper wire
·PVC/Nylon insulation
· Aluminum-plated foil and tinned copper braid
·PVC jacket
·Temperature range -40° C to +90° C (-40° F to +194° F)
This design ensures that no humidity can be trapped in the lead.
78
SHIELDED
New Style Shielded Primary Leads for MOTORTECH AlphaRail Wiring Rails
P/N1) Supersedes Description Ignition Coil Connector Wiring Rail Connector Conductor Equivalent to
95.01.140-L Primary lead MIL Style 3 pole socket, 180° MIL Style 2 pole pin, 180° 2 wire 95.01.040-L
95.01.141-L Primary lead MIL Style 3 pole socket, 90° MIL Style 2 pole pin, 180° 2 wire 95.01.041-L
95.01.142-L Primary lead MIL Style 2 pole socket, 180° MIL Style 2 pole pin, 180° 2 wire 95.01.042-L
95.01.143-L Primary lead MIL Style 2 pole socket, 90° MIL Style 2 pole pin, 180° 2 wire 95.01.043-L
95.01.144-L Primary lead MIL Style 3 pole socket, 180° MIL Style 2 pole pin, 90° 2 wire 95.01.044-L
95.01.145-L Primary lead MIL Style 3 pole socket, 90° MIL Style 2 pole pin, 90° 2 wire 95.01.045-L
95.01.146-L Primary lead MIL Style 2 pole socket, 180° MIL Style 2 pole pin, 90° 2 wire 95.01.046-L
95.01.147-L Primary lead MIL Style 2 pole socket, 90° MIL Style 2 pole pin, 90° 2 wire 95.01.047-L
Standard lead lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
1)
Add suffix "-X" to part number for cross wired primary leads for positive grounded ignition systems.
SYSTEMS
IGNITION
Conventional Shielded Primary Leads for MOTORTECH AlphaRail Wiring Rails
P/N1) Supersedes Description Ignition Coil Connector Wiring Rail Connector Conductor Equivalent to
95.01.040-L Primary lead MIL Style 3 pole socket, 180° MIL Style 2 pole pin, 180° 2 wire
95.01.041-L Primary lead MIL Style 3 pole socket, 90° MIL Style 2 pole pin, 180° 2 wire
95.01.042-L Primary lead MIL Style 2 pole socket, 180° MIL Style 2 pole pin, 180° 2 wire
95.01.043-L Primary lead MIL Style 2 pole socket, 90° MIL Style 2 pole pin, 180° 2 wire
95.01.044-L Primary lead MIL Style 3 pole socket, 180° MIL Style 2 pole pin, 90° 2 wire
95.01.045-L Primary lead MIL Style 3 pole socket, 90° MIL Style 2 pole pin, 90° 2 wire
95.01.046-L Primary lead MIL Style 2 pole socket, 180° MIL Style 2 pole pin, 90° 2 wire
95.01.047-L Primary lead MIL Style 2 pole socket, 90° MIL Style 2 pole pin, 90° 2 wire
Standard lead lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
1)
Add suffix "-X" to part number for cross wired primary leads for positive grounded ignition systems.
79
PRIMARY LEADS
95.01.010-L Primary lead MIL Style 3 pole socket, 180° 1/2-14 NPT, 180° 2 wire 593022-L
95.01.010-L-2 Primary lead MIL Style 3 pole socket, 180° 1/4-18 NPT, 180° 2 wire
95.01.010-L-3 Primary lead MIL Style 3 pole socket, 180° 3/8-18 NPT, 180° 2 wire
95.01.020-L Primary lead MIL Style 3 pole socket, 90° 1/2-14 NPT, 180° 2 wire 593027-L
95.01.020-L-2 Primary lead MIL Style 3 pole socket, 90° 1/4-18 NPT, 180° 2 wire
95.01.020-L-3 Primary lead MIL Style 3 pole socket, 90° 3/8-18 NPT, 180° 2 wire
95.01.021-L Primary lead MIL Style 3 pole socket, 90° 1/2-14 NPT, 180° 2 wire 593029-L
95.01.022-L 2)
Primary lead MIL Style 3 pole socket, 90° 1/2-14 NPT, 180° 2 wire 593036-L
95.01.023-L2) Primary lead MIL Style 3 pole socket, 180° 1/2-14 NPT, 180° 2 wire 593035-L
1)
Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in., 96 in., 108 in., 120 in., 135 in., 138
in., 150 in.; other lengths available on request.
2)
Wire length is double of braid length.
95.06.010-L Primary lead MIL Style 2 pole socket, 180° 1/2-14 NPT, 180° 2 wire A754-L / LT2001-L
95.06.020-L Primary lead MIL Style 2 pole socket, 90° 1/2-14 NPT, 180° 2 wire B754-L / LT2011-L
95.06.030-L Primary lead MIL Style 2 pole socket, 180° 5/8-24 NPT, 90° 2 wire C754-L / LT2100-L
Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in., 96 in., 108 in., 120 in., 135 in.,
1)
95.01.030-L Primary lead MIL Style 3 pole socket, 90° MIL Style 3 pole socket, 180° 2 Wire 539069-L
95.01.031-L Primary lead MIL Style 3 pole socket, 90° MIL Style 3 pole pin, 90° 2 Wire
95.01.033-L Primary lead MIL Style 3 pole socket, 90° MIL Style 3 pole socket, 180° 3 Wire
1)
Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
95.01.032-L Primary lead MIL Style 2 pole pin, 90° MIL Style 2 pole pin, 90° 2 Wire
1)
Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
Adaptor
Outlet Box -L Coil Connector
80
Shielded Cable Assemblies
P/N1) Supersedes Description Ignition Coil Connector Wiring Rail Connector Conductor Equivalent to
95.01.011-L Cable assembly MIL Style 3 pole socket, 180° 1/2-14 NPT, 180° 3 wire
95.01.024-L Cable assembly MIL Style 3 pole socket, 90° 1/2-14 NPT, 180° 3 wire 593024-L
95.01.025-L Cable assembly MIL Style 4 pole socket, 90° 1/2-14 NPT, 180° 5 wire 593025-L
95.01.026-L Cable assembly MIL Style 5 pole socket, 90° 1/2-14 NPT, 180° 6 wire 593026-L
1)
Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
NEW
SYSTEMS
Primary Leads for MOTORTECH AlphaRail Wiring Rails - For Non-Shielded Applications
IGNITION
P/N1) Supersedes Description Ignition Coil Connector Wiring Rail Connector Conductor Equivalent to
06.01.040-L Primary lead MIL Style 3 pole socket, 180° MIL Style 2 pole pin, 180° 2 wire
06.01.041-L Primary lead MIL Style 3 pole socket, 90° MIL Style 2 pole pin, 180° 2 wire
06.01.042-L Primary lead MIL Style 2 pole socket, 180° MIL Style 2 pole pin, 180° 2 wire
06.01.043-L Primary lead MIL Style 2 pole socket, 90° MIL Style 2 pole pin, 180° 2 wire
06.01.044-L Primary lead MIL Style 3 pole socket, 180° MIL Style 2 pole pin, 90° 2 wire
06.01.045-L Primary lead MIL Style 3 pole socket, 90° MIL Style 2 pole pin, 90° 2 wire
06.01.046-L Primary lead MIL Style 2 pole socket, 180° MIL Style 2 pole pin, 90° 2 wire
06.01.047-L Primary lead MIL Style 2 pole socket, 90° MIL Style 2 pole pin, 90° 2 wire
Standard lead lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
1)
Add suffix "-X" to part number for cross wired primary leads for positive grounded ignition systems.
Primary Leads for CUMMINS® QSK60G and QSV81/91G Gas Engines NEW
P/N Supersedes Description Ignition Coil Connector Wiring Rail Connector Conductor Equivalent to
06.30.142-141) Primary lead MIL Style 3 pole socket, 90° 3 pole socket, 180° 2 wire
1)
Fits application only, if conversion kits P/N 75.30.143 or 75.30.144 previously were used; other lengths available on request.
06.30.111-60 1)
Primary lead 2 wire, 180° MIL Style 3 pole socket, 180° 2 wire 583017-60KT
1)
Standard lead length 60 inch; other lengths available on request.
06.30.095-L Primary lead MIL Style 3 pole socket, 90° 3 pole socket, 180° 2 wire
06.30.107 Primary lead MIL Style 3 pole socket, 90° 3 pole socket, 180° 2 wire A740746
06.30.108 Primary lead 2 wire, 180° 3 pole socket, 180° 2 wire 740746B
1)
Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.
81
82
EXTENSIONS
Hundreds of different engine models in this industry call for a great number of variations of unshielded and
shielded Spark Plug Extensions, Coil Extensions and Repair Kits.
Main purpose of an extension is to ensure that the high voltage can pass from the ignition coil to the spark plug.
MOTORTECH has engineered a great number of excellent designs for high end or low end markets.
83
EXTENSIONS
PolyMot™
MOTORTECH SPARK PLUG LEADS & EXTENSIONS
84
D
NON-SHIELDE
PolyMot Spark Plug Extensions
Extension P/N Silicone Thread on
P/N Supersedes Engine Make Model Resistance Spark Plug Equivalent to
Length Seal Ring Top End
06.80.320/H/H-T/
06.80.320-T CATERPILLAR® G3500 series 11 in. 5 kΩ GI3-1/RB77WPCC 06.84.040 x 123-4710
06.80.381H/H-T
SYSTEMS
IGNITION
06.80.461 WÄRSTSILÄ® 34SG series 17 in. 5 kΩ GI3-1/RB77WPCC 06.84.040 0012E006500
AT25GL
06.80.330-T 06.80.330 WAUKESHA® 15 in. 5 kΩ GI3-1/RB77WPCC 06.84.040 x A211797Y
series
AT27GL
06.80.213-T 06.80.213 WAUKESHA® 15 in. 5 kΩ GT3-1/RM77N 06.84.040 x A296064G
series
AT27GL-LR
06.80.310-T 06.80.310 WAUKESHA® 14 in. 5 kΩ GI3-1/RB77WPCC 06.84.040 x A296064H
series
A211797J/
06.80.309-T 06.80.309 WAUKESHA® VGF series 9 in. 5 kΩ GI3-1/RB77WPCC 06.84.040 x
A211797K
A211797H/
06.80.321-T 06.80.321/H/H-T WAUKESHA® VHP-GL series 13 in. 5 kΩ GI3-1/RB77WPCC 06.84.040 x
A211797P
1)
Fits application only, if conversion kits P/N 75.30.143 or 75.30.144 previously were used.
PolyMot Spark Plug Extensions – Removal Tool for Spark Plug Extensions with Thread on Top End
P/N Coil Connection
85
EXTENSIONS
D
NON-SHIELDE
Repair Kits for MOTORTECH Ignition Coils – For CATERPILLAR® G3400 and G3500 Series Gas Engines
P/N Figure Description Application Extension Length Extension Diameter Fits Ignition Coil P/N
06.80.743 1 Ignition coil repair kit G3400 – Non CSA 107 mm 30 mm 06.50.143/06.50.147
06.80.751 1 Ignition coil repair kit G3500 – Non CSA 118 mm 30 mm 06.50.151/06.50.155
06.80.753 1 Ignition coil repair kit G3500 – Non CSA 112 mm 30 mm 06.50.153/06.50.157
Repair Kits for CATERPILLAR® Ignition Coils – for CATERPILLAR® G3400 and G3500 Series Gas Engines
P/N Figure Supersedes Description Application Extension Length Extension Diameter Fits Ignition Coil P/N
06.80.742 1 06.80.418H Ignition coil repair kit G3400 - CSA 97 mm 30 mm 232-6349, 165-1592, 122-8070
06.80.420H 1 Ignition coil repair kit G3400 - Non CSA 107 mm 30 mm 232-6352, 213-7443
06.80.744 1 06.80.417H Ignition coil repair kit G3400 - CSA 109 mm 30 mm 232-6353, 213-7444
06.80.515H 1 06.80.315H Ignition coil repair kit G3500 - Non CSA 118 mm 30 mm 232-6346, 165-1589, 124-0749
06.80.752 1 06.80.415H Ignition coil repair kit G3500 - CSA 105 mm 30 mm 232-6347, 165-1590
06.80.480 1 Ignition coil repair kit G3500 - Non CSA 112 mm 30 mm 232-6350
06.80.754 1 06.80.415H Ignition coil repair kit G3500 - CSA 105 mm 30 mm 259-2078
86
Teflon Extensions for CATERPILLAR® Ignition Coils
P/N Figure Description Extension Length Extension Diameter Equivalent to
Spark Plug Extension for MOTORTECH/CATERPILLAR® Ignition Coil – For CATERPILLAR® G3520C and G3600 Series Gas Engines1)
P/N Figure Description Application Resistance Extension Length Extension Diameter Fits Ignition Coil P/N Equivalent to
CSA Certified Integral Ignition Coil Adaptors for shielded Spark Plugs
SHIELDED
P/N1) Figure Description Spark Plug Connection Terminal Well Depth Ignition Coil Connection Terminal Well Depth Equivalent to
SYSTEMS
IGNITION
95.07.010-L 4 Integral ignition coil adaptor 5/8-24 UNEF 1 in. 1-20 UNEF 2 in. BG E Series
95.07.011-L 4 Integral ignition coil adaptor 3/4-20 UNEF 1 in. 1-20 UNEF 2 in. 593120-L / M"L"-2C
95.07.012-L 4 Integral ignition coil adaptor 3/4-20 UNEF 2 in. 1-20 UNEF 2 in. 593130-L / M"L"1C
95.07.013-L 4 Integral ignition coil adaptor 13/16-20 UNEF 2 in. 1-20 UNEF 2 in. 593140-L
1)
Standard lengths ("-L") = 1.5 in., 3 in., 6 in., 9 in., 11 in., 19 in.; other lengths available on request.
95.07.020-L 5 Shielded spark plug extension 5/8-24 UNEF 1 in. 5/8-24 UNEF 1 in.
95.07.021-L 5 Shielded spark plug extension 3/4-20 UNEF 1 in. 3/4-20 UNEF 1 in. M"L"-2S
95.07.022-L 5 Shielded spark plug extension 3/4-20 UNEF 2 in. 3/4-20 UNEF 2 in. M"L"-2E
95.07.023-L 5 Shielded spark plug extension 5/8-24 UNEF 1 in. 3/4-20 UNEF 2 in.
95.07.024-L 5 Shielded spark plug extension 3/4-20 UNEF 1 in. 3/4-20 UNEF 2 in.
1)
Standard lengths ("-L") = 4 in., 5 in., 6 in., 8 in., 10 in., 12 in., 18 in.; other lengths available on request.
1 2 2 3 4
87
88
WIRING RAIL SYSTEMS
SYSTEM
MOTORTECH wiring rails are available for ignition, detonation detection and thermocouple wiring.
They are made of stainless steel which performs better than aluminum in harsh environments and where operators
use any kind of equipment to hold or stand on. Rigid military style connectors are securely fastened into stainless
steel. No screws will come loose when the engine vibrates as the AlphaRail is assembled with watertight industrial
rivets (used as joints in the aircraft industry).
Rails are filled with special foam to ensure that all wires are separated from ground and will not vibrate and
eventually short out to ground. It‘s a water proof design built to last in an uncovered environment.
Don‘t go low-tech and take the risk of engine down time because of equipment being under repair. Eliminate the
need for constant rewiring, connector exchanges or straightening out weak and bent aluminum wiring rails.
89
WIRING RAIL SYSTEMS
90
Application Chart – Common Igniton Wiring Rails
SYSTEMS
IGNITION
Harness Junction Box
Ignition Coil
Mounting Brackets
Wiring Rail Amount of
Engine Information Amount of
Amount of Amount of Amount of Junction Box
Amount of Amount of Harness
Flatbar
Amount of Amount of Flatbar optional Flatbar optional Ignition Coils P/N 95.40.314-L P/N 6.05.067
Cylinder Ignition Bracket .120 P/N 75.10.280
Number of Ignition Wiring Rail Wiring Rails P/N 75.10.303 P/N 75.10.097 P/N 75.10
Engine Model Arrange- Cylinders Coils per
Engine Make 1 1
ment Cylinder 2 4
2 2
1 2 1 1
2 2 95.87.222-NAN-10 2 6
In-Line 2 2
AJAX DPC-300 2 1
95.87.323-NAN-10 1 12 2
In-Line 3 2 8 8
DPC-600 8 8 1
AJAX 2 2
12 1 95.86.611-NBN 8 16
V-Type 8 8
CATERPILLAR G398 8 1
95.86.811-NDN 2 4 1
V-Type 16 1 2 2
G399 2 2 1
CATERPILLAR 1 1
4 1 95.86.406-NAN 2 6
In-Line 2 2
CATERPILLAR G3304 2 1
95.86.606-NAN 1 6 1
In-Line 6 1 2 2
G3306 2 2 1
CATERPILLAR 1 2
6 1 95.86.607-NAN 4 8
In-Line 4 4
CATERPILLAR G3406 4 1
95.86.407-NAN 2 16 2
V-Type 8 1 6 6
G3408 6 6 1
CATERPILLAR 2 2
16 1 95.86.811-NAN 6 12
V-Type 6 6
CATERPILLAR G3516 6 1
95.86.618-NAN 2 8 1
V-Type 12 1 6 6
G3612 6 6 1
CATERPILLAR 1 2
8 1 95.86.814-NAN 8 20
In-Line 8 8
COOPER BESSEMER G2408GTL 8 1
95.87.548-NGN-04 2 20 2
V-Type 10 2 8 8
GMVA-10 8
COOPER BESSEMER 2 8 2 1
10 2 95.87.541-NEN-10 4 8
V-Type 4 4
COOPER BESSEMER GMW_ -10 4 1
95.86.406-NAN 2 24 2
V-Type 8 1 6 6
DAEWOO GV TIR/CIR 158 6 6 1
95.87.622-NAN-04 2 16 2
V-Type 12 2 8 8
HVA-12 8 8 1
DeLAVAL 2 2
16 1 95.86.809-NAN 4 8
V-Type 4
DEUTZ TBG 620 V16 4 4 1
95.86.410-NAN 2 6 2
V-Type 8 1 4 4
DEUTZ TCG 2015 V8 4 4 1
95.86.310-NAN 2 12 2
V-Type 6 1 6 6
DEUTZ TCG 2015 V6 6 6 1
95.87.344-NAN-04 2 12 2
V-Type 6 2 8 8
KVS-6 8 8 1
INGERSOLL RAND 2 2
12 1 95.86.627-NDN 8 12
V-Type 8 8
INGERSOLL RAND PKVG -12 8 1
95.86.627-NFN 2 8 2
V-Type 12 1 4 4
PKVGR -12 4 4 1
INGERSOLL RAND 2 2
8 1 95.86.437-NAN 4 12
V-Type 4 4
INGERSOLL RAND XVG -8 4 1
95.86.606-NAN 2 6 1
V-Type 12 1 3 3
E2842E312 3 3
MAN 1
6 1 95.86.613-NAN
6G825 In-Line
SUPERIOR
Charts:
...
Specification
ch.de
www.motorte
91
WIRING RAIL SYSTEMS
SHIELDED
Wiring Rail Kits for CATERPILLAR® G3300 Series Gas Engines – Shielded Ignition
P/N
95.75.025-1 Ignition wiring rail kit without ignition unit for CATERPILLAR® G3304
• Incl. harness to ALTRONIC® magneto
• Mounting bracket welded to the rail
• G-lead connector
• 4 shielded primary leads P/N 95.01.040-15 to fit ALTRONIC® 3 pole integral ignition coils
• 1 Timing adaptor P/N 06.98.109
95.75.024-1 Ignition wiring rail kit without ignition unit for CATERPILLAR® G3306
• Incl. harness to ALTRONIC® magneto
• Mounting bracket welded to the rail
• G-lead connector
• 6 shielded primary leads P/N 95.01.040-15 to fit ALTRONIC® 3 pole integral ignition coils
• 1 Timing adaptor P/N 06.98.109
Wiring Rail Kits for CATERPILLAR® G3600 Series Gas Engines – Ignition / Detonation
P/N Description Engine Make Engine Model Ignition Controller Ignition Coil Primary Lead Equivalent to
95.75.106 Wiring rail kit CATERPILLAR® G3612 not included not included 95.01.045-12 191-5007 / 191-5008
92
Wiring Rail Kits for ARROW® Gas Engines – Shielded Ignition
P/N Description Engine Make Engine Model Ignition Controller Ignition Coil Primary Lead Equivalent to
77.75.016 Wiring rail kit DEUTZ® TBG620V16 not included 06.50.055 06.85.179-20
SYSTEMS
IGNITION
Wiring Rail Kit for WAUKESHA® Gas Engines
P/N Description Engine Make Engine Model Ignition Controller Ignition Coil Primary Lead Equivalent to
STOP
93
WIRING RAIL SYSTEMS
D
NON-SHIELDE
Ignition Kits for MAN® Gas Engines – Non-Shielded
P/N Description Engine Make Engine Model Ignition Controller Ignition Coil High Tension Lead Pickup
94
Ignition Kits for LIEBHERR® Gas Engines – Non-Shielded
P/N Description Engine Make Engine Model Ignition Controller Ignition Coil Spark Plug1) Pickup2)
75.00.434 Ignition kit LIEBHERR® G946 66.00.410-8 06.50.107 not included LIEBHERR® pickup
75.00.436 Ignition kit LIEBHERR® G9512 66.00.410-16 06.50.107 not included LIEBHERR® pickup
1)
MOTORTECH XTL PLUG P/N B432BEX9-A107 has to be ordered separately in required quantity.
2)
Scope of supply only includes pickup wiring.
SYSTEMS
IGNITION
75.00.290 Ignition kit ARROW® VRG330 06.00.520 06.50.102 06.85.860-14 66.60.001-125
95
WIRING RAIL SYSTEMS
95.75.338 Ignition kit CATERPILLAR® G3304 06.00.520 not included 95.01.040-16 95.70.003-60
1)
Shielded ignition coils have to be ordered separately. P/N 95.09.040-6 for CATERPILLAR® G3304/G3306. P/N 95.09.040-12 for CATERPILLAR® G3406.
2)
Suitable trigger conversion kit included in each ignition kit.
D
NON-SHIELDE
The Century of Ignition Magnetos is over.
Move forward to the generation of electronic ignition.
96
1 Ignition Kit for CATERPILLAR® G3304
∙ Preprogrammed MIC520 ignition controller
∙ Wiring rail with ignition coils and brackets
∙ Harnesses for in- and output
∙ Pickup
∙ High tension leads
∙ Mechanical trigger kit with disc and adapter ring/gaskets
∙ Magneto drive cover plate and gasket
SYSTEMS
IGNITION
2 Ignition Kit for CATERPILLAR® G3306
∙ Preprogrammed MIC520 ignition controller
∙ Wiring rail with ignition coils and brackets
∙ Harnesses for in- and output
∙ Pickup
∙ High tension leads
∙ Mechanical trigger kit with disc and adapter ring/gaskets
∙ Magneto drive cover plate and gasket
Optional available:
Tool for CATERPILLAR® G3406
Fork spanner, swan-necked for easy
removal of camshaft drive gear.
P/N 44.04.005
97
98
TOOLS AND TEST EQUIPMENT
Service Engineers today are constantly under pressure to keep the engine downtime as short as possible.
For this reason MOTORTECH has designed a wide range of test equipment and tools.
Electrical problems can create frustration to those who have to deal with it on a daily base.
We try harder every day to design and manufacture what you are looking for!
99
TOOLS AND TEST EQUIPMENT
NEW
SparkView MOTORTECH HIGH VOLTAGE INDICATOR
06.90.099-100 1 SparkView high voltage indicator incl. SparkScan1 high voltage clamp P/N 06.90.100
06.90.099-105 2 SparkView high voltage indicator incl. BNC cable P/N 06.90.105
1 2
100
SparkScan1 MOTORTECH IGNITION ACCESSORIES
SYSTEMS
IGNITION
SparkScan1 – High Voltage Clamp
P/N Description Length
101
TOOLS AND TEST EQUIPMENT
ICT
MOTORTECH IGNITION COIL TESTER
06.98.054 Ignition coil tester incl. adaptor kits for popular ignition coils
Ignition Coil Tester – Adaptor Kits - Standard1) – including Teflon Ignition Coil Adaptors and Connecting Leads
Connections of included Lead
06.98.054-1 Adaptor kit – CATERPILLAR® ignition coils DEUTSCH® connector XLR connector
06.98.054-3 Adaptor kit – MOTORTECH style ignition coils 2 pole XLR connector
06.98.054-4 Adaptor kit – Flange ignition coils MIL Style 3 pole socket, 180° XLR connector
06.98.054-5 Adaptor kit – CSA certified integral ignition coils, outer thread MIL Style 2/3 pole socket, 180° XLR connector
06.98.054-6 Adaptor kit – CSA certified integral ignition coils, inner thread MIL Style 2/3 pole socket, 180° XLR connector
06.98.054-7 Adaptor kit – CSA certified ignition coils, externally mounted MIL Style 2/3 pole socket, 180° XLR connector
1)
All adaptor kits included in ignition coil tester.
Ignition Coil Tester – Adaptor Kits – Non Standard – including Connecting Leads
Connections of included Lead
06.70.192-5 Adaptor kit – CUMMINS® ignition coil P/N 3964547 4 pole, 180° XLR connector
102
Adaptor Kits – Standard
Test Arrangement
SYSTEMS
IGNITION
Test of CATERPILLAR® ignition coil Test of flange ignition coil
Oscilloscope not included in scope of supply. Oscilloscope not included in scope of supply.
103
TOOLS AND TEST EQUIPMENT
IPS
MOTORTECH IGNITION PICKUP SIMULATOR
07.70.002-1 2)
IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.508) with inductive pickup
07.70.002-22) IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.508) with hall-effect pickup
07.70.002-3 2)
IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.508) with magnetic pickup
07.70.004 IPS adaptor kit - MOTORTECH MIC500 (P/N 06.00.513/06.00.514), ALTRONIC® DISN, CATERPILLAR® 163-6164/163-6108
07.70.010 IPS adaptor kit - MOTORTECH MIC500 (P/N 06.00.515-6/06.00.515-8/06.00.516/06.00.517), WAUKESHA® CEC (VHP/VGF series)
104
ScopeLite MOTORTECH TIMING LIGHT
SYSTEMS
IGNITION
Function saves the 2 built in 9V batteries in case the operator
forgets to turn off power.
Make it easy and safe for the Operator!
06.98.100-200 ScopeLite LED timing light, incl. clamp, 200 in. standard connecting lead and carrying case
ScopeLite – MOTORTECH Timing Light – Connecting leads (Standard and Non Standard Lengths1))
P/N Description Length
105
TOOLS AND TEST EQUIPMENT
Digital Protractor
The digital protractor is a compact rotational angle measuring
tool. The unit is equipped with magnets for easy and flexible
installation on flywheel, camshaft, pully or any other rotating
shaft gear.
P/N Description
44.99.918 High tension lead removal tool for MAN® gas engines
Workshop Equipment
P/N Picture Description
06.05.903-1 1 Spark plug test stand for M14 and M18 spark plugs
1 2
106
Harness Connector Assembly Tools
P/N Picture Description
SYSTEMS
IGNITION
06.98.047 4 Crimping tool for P/N 06.80.126 (already included crimping tool insert P/N 06.98.048)
06.98.048 9 Crimping tool insert for P/N 06.98.047 to crimp terminal P/N 06.80.126
06.98.050 10 Crimping tool insert for P/N 06.98.047 to crimp terminal P/N 22.85.802 and P/N 22.85.803
1 2 3 4
6 7 8 9 10
107
108
SPARK PLUGS AND ACCESSORIES
As the market changes due to emission regulations, new fuel qualities, higher energy ignition or only to the
demand for higher efficiency, the request for better spark plugs has been raised. The Industrial Spark Plug
manufacturers have done their homework and offer today all kinds of spark plugs with special electrode
materials or even completely new firing end designs.
109
SPARK PLUGS AND ACCESSORIES
Features
• No more trapped air in the extension barrel
• No more condensation
• No internal flash over
• Built in ceramics
• High dielectric strength
• Rigid welds
The J-Type ground electrode ensures The alternative X-Type double-stage
better combustion, particularly on electrodes are ideally suited for
lean burn gas engines. slow-speed gas engines.
XT-Plugs
MOTORTECH EXTENDED SPARK PLUGS
MOTORTECH XT-PLUGS
MOTORTECH XT-PLUGS are available with three different termi-
nal styles to be connected directly to a high tension lead or a
short integral ignition coil.
The “S2-Type” has a 5/8 The “DCP-Type” has a The “C-Type” is an exten-
in. male thread and used female thread to adapt to ded barrel plug that has
to be called the AIRCRAFT a short integral ignition a conventional ceramic
STYLE spark plug. This coil. This combination is insulator on the top end.
spark plug is designed to popular in some applica- This allows the use of a
be connected to a shiel- tions, where customers standard spark plug boot.
ded high tension lead. have had bad experien- Preferable a connector
ces with shielded high that includes a 5 kΩ resis-
tension leads. tor to suppress the RFI.
110
Specification Table – MOTORTECH XT Plugs
E
C
D
B
F
A A A
B = Thread Size
B4 = M14 x 1.25
B8 = M18 x 1.5
B7 = 7/8 in.
C = Thread Reach
1 = 0.500 in.
PLUGS
SPARK
2 = 0.600 in.
3 = 0.750 in.
D = Electrode Design
1 = X-Type
2 = J-Type
optional
F = Electrode Gap
010 = 0.010 in. / 0.25 mm
012 = 0.012 in. / 0.30 mm
014 = 0.014 in. / 0.35 mm
Recommended Tightening Torque1)
P/N A B C D E - F
Please observe the tightening torques rendered by each
1)
engine manufacturer.
111
SPARK PLUGS AND ACCESSORIES
F
D C
E A
G H
B
1 1a 2 3 4 5* 6 7 8 9
112
Specification Table – MOTORTECH XTL Plugs for non shielded Applications
PLUGS
SPARK
BEX8 = 8 in. 5B = CSA – BENDIX® Style – Externally Mounted – 3/4-20 UNEF
BEX10 = 10 in. 5C = CSA – MOTORTECH Style – Externally Mounted – 1-20 UNEF
BEX12 = 12 in. 6 = Non CSA – ALTRONIC® Style – male, 90°
BEX16 = 16 in. 7 = Non CSA – New MOTORTECH Style – M6, 180°
8 = Non CSA – ALTRONIC® Style – female, 90°
H = Electrode Gap
010 = 0.010 in. / 0.25 mm
012 = 0.012 in. / 0.30 mm
014 = 0.014 in. / 0.35 mm
1)
Other barrel and lead lenghts
available on request.
P/N A B C D - E F G - H
Please observe the tightening torques rendered by each
1)
engine manufacturer.
113
SPARK PLUGS AND ACCESSORIES
G F E
H D
B
I
C
114
Specification Table – MOTORTECH XTL Plugs for shielded Applications
B7 = 7/8-18 12 = 12 in.
14 = 14 in.
16 = 16 in.
C = Thread Reach 18 = 18 in.
1 = 0.500 in.
2 = 0.600 in.
3 = 0.750 in. H = Connector to Ignition Coil
5A = CSA - ALTRONIC® Style – Externally Mounted – 3/4-20 UNEF
5B = CSA - BENDIX® Style–- Externally Mounted – 3/4-20 UNEF
D = Electrode Design 5C = CSA - MOTORTECH Style – Externally Mounted – 1-20 UNEF
1 = X-Type
PLUGS
SPARK
2 = J-Type optional
I = Electrode Gap
E = Extended Barrel Length1) 010 = 0.010 in. / 0.25 mm
BEX6 = 6 in. 012 = 0.012 in. / 0.30 mm
BEX8 = 8 in. 014 = 0.014 in. / 0.35 mm
BEX10= 10 in.
BEX12= 12 in. 1)
Other barrel and lead lenghts
BEX16= 16 in. available on request.
P/N A B C D E - F G H - I
Please observe the tightening torques rendered by each
1)
engine manufacturer.
115
SPARK PLUGS AND ACCESSORIES
NEW
MOTORTECH MPC Pre-Chamber Spark Plug1)
MOTORTECH introduces the new high quality pre-chamber
spark plug series. First to come is the M18 x 1.5 with
3/4 in. thread reach.
• New design
• High quality electrode material
• Designed for long life
• Industrial rigid construction
P/N Description Thread Size Thread Reach Electrode Design Hex Equivalent to
MPC1800 MPC spark plug M18 x 1.5 0.750 in. Pre-chamber 7/8 in.
1)
MOTORTECH MPC spark plugs only available in packs of 4 pcs.
MOTORTECH ICP Spark Plugs with Dual Thread for use with Integral Ignition Coils1)
For Operators who prefer to use a long integral ignition coil, All plugs have iridium center and ground electrodes. For years
MOTORTECH manufactures the dual threaded spark plugs. these plugs have been successfully operated worldwide.
These are available in M14 and M18 thread sizes.
P/N Description Thread Size Thread Reach Electrode Design Hex Thread Size Ignition Coil Equivalent to
ICPB412 ICP spark plug M14 x 1.25 0.500 in. J-Type 15/16 in. 13/16-20 UNEF RTL85G
ICPB432 ICP spark plug M14 x 1.25 0.750 in. J-Type 15/16 in. 13/16-20 UNEF RTN79G
ICPB812 ICP spark plug M18 x 1.5 0.500 in. J-Type 15/16 in. 13/16-20 UNEF RTM77N
ICPB832 ICP spark plug M18 x 1.5 0.750 in. J-Type 15/16 in. 13/16-20 UNEF RTB77WPCC
1)
MOTORTECH ICP spark plugs only available in packs of 4 pcs.
116
All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.
117
PLUGS
The DDI's key to long plug life
DENSO has launched the latest generation of hardwearing spark plugs − the DENSO DOUBLE IRIDIUM (DDI) spark plug.
DDI spark plug technology improves and extends the spark plug's lifespan and requires significantly less maintenance than
competitor spark plugs. The DDI spark plug is particularly effective when used in biogas engines.
Try DENSO DDI spark plugs today.
Convergence Electrical
laser welding Iridium alloy pad resistance welding Platinum alloy pad
Iridium alloy
(biogas) (biogas)
0 Hours 0 Hours
118
Key to high reliability
10% up up to 5kV
PLUGS
SPARK
Conventional Plug Conventional Plug
NORMAL PLUG
Special Nickel Plating With
Better Corrosive Resistance
Better corrosive resistance for con-
densed acid water. Exposure Test By
Analyzed by DENSO
Analyzed by DENSO
119
The SAVER's key to long plug life
DENSO's OEM expertise and commitment to innovation enables them to remain at the forefront of cutting-edge gas engine
spark plug development. The unique and specialist technology used in the Iridium Saver and Iridium Saver Performer spark
plugs range extends their lifespan, making them ideal for high-compression lean-burn engines. Iridium Saver and Iridium
Performer spark plugs also help to maximise engine performance and deliver extra durability. Because they require minimal
maintenance compared to standard plugs, Iridium Saver and Iridium Saver Performer spark plugs increase service interval
times. Try DENSO's Iridium Saver or Iridium Saver Performer spark plugs today.
Cross Groove
Iridium alloy
20 25 30
Conventional Plug
FEM
4kV
Ground Electrode
IRIDIUM SAVER
Required Voltage (kV)
PERFORMER
Center Electrode
Ground Electrode
IRIDIUM SAVER
Center Electrode
CONVENTIONAL PLUG
(Electric Field Strength)
Weak Strong
(spark easier)
(V12 Engine, Natural Gas)
0 Hours
The above is analysed by DENSO
120
Specifications and cross reference
G I 3 - 1 ( A )
for Gas Engines
E 19 mm 1.
Iridium pad without cross groove on center electrode
20.8 mm and Platinum pad on ground electrode.
N M 14 x 1.25 12.7 mm 3.
For vehicle
All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.
5.
Iridium pad without cross groove on center electrode
K 16 mm 19 mm
and Iridium pad on ground electrode.
1.
L 20.8 mm
Iridium pad with cross groove on center electrode
and Platinum pad on ground electrode.
PLUGS
SPARK
20.6 mm
3.
I M 18 x 1.5 Iridium pad without cross groove on center electrode
and Platinum pad on ground electrode.
22.2 mm
5.
T 13.8 mm Iridium pad without cross groove on center electrode
and Iridium pad on ground electrode.
Cross Reference
CHAMPION® STITT® ALTRONIC® BERU®
14R-3CPU / 14-3CPU /
GE3-1 GE3-5
14R-5DPU / 14R-4CDP
RN79G (0.015) 407XL / R407XL J1463DP
14R-4CIU (Z187) / 14R-4CIU2 (Z215)
GE3-5
/ 14R-4DIU2 (Z258) / 14R-4DIU3
RN79G (0.020) 14R-4CIU (Z205) GE5-1
M14
RC78PYP /
14FR-4DPUO GK3-1
RC78PYP15
GK3-5
RC78WYP15 14FR-4DIU
121
Spark Plugs M14
10.2
43
37.1
70 36.3
Ø 12.2
56.1 50.4
Ø 12.2 Ø 10.5
12.7
122
Spark Plugs M18
10.2 10.2
63.5 65
Ø 6.4 Solid terminal
Ø 14.4 Ø 14.4 ISO 14508
89 89 10.2
All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.
46.4
Hex 22.2
Hex 20.8
Ø 14.4 69.7
PLUGS
SPARK
Hex 22.2
M18X1.5 M18X1.5
20.6 20.6
M14X1.5
13.8
GI3-3 GL3-3
Inital Gap Inital Gap
0.28 mm 0.28 mm
GI3-5 GL3-5
Inital Gap Inital Gap
Double 0.28 mm Double 0.28 mm
Iridium Iridium
123
SPARK PLUGS AND ACCESSORIES
Torque Wrench
P/N Supersedes Description Drive
07.98.063 Torque wrench, 200 Nm/150 ft./lb. 1/2 in. / 3/8 in.
Extended Barrel Magnetic Spark Plug Sockets – 1/2 Inch Drive - Standard Versions1)
P/N Supersedes Description Hex Drive
07.99.022-2-L 07.99.020-L Magnetic spark plug socket 15/16 in. 1/2 in.
07.99.022-3-L 07.99.019-L Magnetic spark plug socket 7/8 in. 1/2 in.
07.99.022-4-L 07.99.018-L Magnetic spark plug socket 13/16 in. 1/2 in.
1)
Standard barrel lengths ("L") = 6 in., 12 in., 16 in., 18 in. Other lengths available on request.
Extended Barrel Magnetic Spark Plug Sockets – 1/2 Inch Drive - Special Versions
P/N Supersedes Description Hex Drive
07.99.022-3-36 Magnetic spark plug socket – NORDBERG® 7/8 in. 1/2 in.
07.99.022-6-6 Magnetic spark plug socket – MAN® 13/16 in. 1/2 in.
07.99.022-6-1 Magnetic spark plug socket – MAN®, Liebherr® 5/8 in. 1/2 in.
07.98.114-12 07.98.022 Seat & thread reconditioner M14 x 1.25 1/2 in.
07.98.114-34 07.98.023 Seat & thread reconditioner M14 x 1.25 3/4 in.
07.98.118-12 07.98.024 Seat & thread reconditioner M18 x 1.5 1/2 in.
07.98.118-34 07.98.025 Seat & thread reconditioner M18 x 1.5 3/4 in.
Thread Lubricant
This lubricant is non-metallic and non-conductive. Guarantees easy spark plug removal and prevents
thread damage. Also for use with seat & thread reconditioner.
P/N Description
124
Spark Plug Cleaning Process Overview
∙ Select the appropriate cleaning nozzle for the spark plug ∙ Screw the threaded spark plug end into the cleaning nozzle.
used based on the following list. ∙ Hold the spark plug tightly during the entire cleaning
– small cleaning nozzle (dia. aperture: 12 mm/0.47'') process.
for spark plugs with M14 thread
– large cleaning nozzle (dia. aperture: 18 mm/0.71'')
for spark plugs with 7/8" or M18 thread
PLUGS
∙ Attach the cleaning nozzle.
SPARK
∙ Actuate the trigger in spurts to perform the cleaning. ∙ Remove the loose residues with compressed air.
The blasting grit is suctioned in and ejected to blast the ∙ When you reuse the cleaned spark plug, adjust the
spark plug surface. The nozzle prevents the blasting grit electrode gap.
from escaping. The blasting grit is collected in the dust ∙ Install new spark plug gasket.
collection bag.
∙ Check the result after a few cleaning blasts. All solid depo-
sits and oil residue should have been lifted off the surface.
NOTE: This is only a short operation overview. Before you use the spark plug cleaning kit, read and understand the original operating manual.
125
SPARK PLUGS AND ACCESSORIES
Made of high quality folded zinc plated steel. To ensure proper spark plug installation and best heat tranfer,
it is important to use a new gasket every time the spark plug is reinstalled.
P/N Description For Thread Size Quantity
Gaskets for Spark Plugs – MOTORTECH ICP Spark Plugs – Dual Threaded Version
P/N Supersedes Description Quantity
Gap Setting Tool for MOTORTECH Spark Plugs with X-Type Electrode Design
A unique electrode design requires a special gapping tool. For spark plugs with X-Type double stage electrodes,
MOTORTECH offers a new and specially designed tool. This makes regapping easy.
P/N Supersedes Description
07.98.113 Gap setting tool incl. gap gauges 0.010 in./0.25 mm, 0.012 in./0.30 mm, 0.014 in./0.35 mm
126
Bench Gap Setting Tool for CHAMPION® Spark Plugs with N-Type Electrode Design
The more professional way to gap N-Type spark plugs is the bench mounted gapping tool.
Each electrode is gapped individually.
P/N Supersedes Description Size
includes:
07.98.101 Spreader
PLUGS
SPARK
07.98.103-014 Gap gauge 0.014 in. / 0.35 mm
Gap Setting Tool for CHAMPION® Spark Plugs with N-Type Electrode Design
P/N Figure Supersedes Description Size
07.98.101 2 Spreader
1 2 3
127
128
GAS ENGINE MANAGEMENT
The All-In-One is a complete genset or CHP unit control system. Forget the days where a genset required multiple
control boxes to be tied together to one system. We have included all functions, including lean burn control into
one unit with large separate display. Tie up to 32 gensets together and connect yourself to the grid. This controller
has the capabilities of a large PLC system at a much lower price !
129
GAS ENGINE MANAGEMENT
130
InteliMains InteliPro or MainsPro
∙ Import/Export ∙ Designed to meet utility ∙ Protective functionalities
∙ Load Sharing protection requirements ∙ Free assignment of 5 relay outputs
∙ Power Plant Managment ∙ Combines standard and ∙ 4 binary switches to remotely
∙ Grid Monitoring optional features change operation of the unit
∙ Advanced communications ∙ Last trip recorded in order to provide Generator
∙ Running Hours Optimization
∙ Data/event logging the evidence of cause of trip ∙ 3 Phase Monitoring
∙ Over/Under Frequency
∙ Over/Under Voltage
∙ Interrupt free reverse synchronizing
∙ Overload Protection
∙ TempByPower load control
∙ Reverse Power Protection
∙ Load Surge Protection
∙ Voltage and PF Control (AVR)
LOAD
MCB GCB
MANAGEMENT
∙ Remote Control ∙ Active/Passive calls ∙ Visualization
GAS ENGINE
∙ Internet Bridge ∙ SMS Service ∙ Programming
CAN2
up to 32 gensets
Engine Managment (ECU)
∙ Speed Measurement/Control
∙ Engine Monitoring and Protection
CAN1
RS 232 / RS 485
∙ Modbus
∙ Direct PC-Connection
∙ Modem Connection
∙ SMS Managment
∙ Active Calls
∙ Internet up to 32 devices
131
GAS ENGINE MANAGEMENT
AIO.Vision (17.0 in.) AIO.Vision (8.0 in.) AIO.Vision (5.7 in.) AIO.NT
P/N 63.50.115 P/N 63.50.101 P/N 63.50.105 P/N 63.50.103
132
ALL-IN-ONE – Gas Engine Management – Other Controllers
P/N Description
63.50.064 Mains supervision controller – IM-NT
63.50.064-BTB Mains supervision controller Bus Tie Breaker – IM-NT BTB
63.50.064-MCB Mains supervision controller Main Circuit Breaker – IM-NT MCB
MANAGEMENT
GAS ENGINE
AIO.NT-Base Box
P/N 63.50.102
IS-AIN8
P/N 63.50.002
IG-AVRi
P/N 63.50.011
IS-BIN 16/8
P/N 63.50.005
IG-AVRi trans
P/N 63.50.010-xxx
IGS-PTM
I-LB+
P/N 63.50.007
P/N 63.50.075
IB-NT IAOUT8
P/N 63.50.112 P/N 63.50.054
133
GAS ENGINE MANAGEMENT
Function
Once the controller detects soft detonation on one of ∙ If this action does not cure the detonation, the load
the sensors (this is a specific stage before real detona- reduction output will be activated.
tion occurs), several steps will take place: ∙ If the load drop does not stop the engine from
∙ Alarm signal turns on detonating the engine STOP output will be activated.
∙ Ignition retard by 0-5 V or 4-20 mA analog output.
STOP
... THIS FROM HAPPENING!
134
Ignition Controller
CAN
Ignition Timing Control
USB (0-5 VDC / 4-20 mA)
Analog Output
MANAGEMENT
GAS ENGINE
Load Reduction
Engine Stop
USB
CAN
Signal from
Ignition Coil
#1 Cylinder
Up to 20 Detonation Sensors
135
GAS ENGINE MANAGEMENT
43.00.020 1)
DetCon20 control unit, 20 outputs, CSA, IP20 x x
43.00.120 DetCon20 control unit, 20 outputs, CSA, in enclosure, includes ignition sensor unit x
DetCon20 – Detonation Control System – Detonation Sensor Lead (1 per Detonation Sensor required)
P/N Description Gas Dual Fuel
DetCon20 – Detonation Control System – ISU Ignition Sensor Unit (1 per System required)
P/N Description Gas Dual Fuel
DetCon20 – Detonation Control System –Inductive Pickup (1 per System required – Dual Fuel Applications only)
P/N Description Gas Dual Fuel
DetCon20 – Detonation Control System – Inductive Pickup Lead (1 per Pickup required – Dual Fuel Applications only)
P/N Description Connector Length Equivalent to Gas Dual Fuel
DetCon20 – Detonation Control System – Trigger Reluctor Pin1) (1 per System required – Dual Fuel Applications only)
P/N Description Diameter Length Equivalent to Gas Dual Fuel
136
NEW
PowerView3 MOTORTECH ENGINE INFORMATION MONITOR
Sample Screens
MANAGEMENT
GAS ENGINE
DetCon Overview Knocking Intensity Trending Knocking Intensity
Screen shows the most important operating data Visualization of knocking intensity of each moni- Visualization of knocking intensity trend data for
of the connected DetCon control unit. tored cylinder. Different colors inform about the each individual cylinder.
system status (Normal – Reduction – Critical).
137
GAS ENGINE MANAGEMENT
• Made of stainless steel which performs better than alumi- • Rails are filled with special foam to ensure that all wires are
num in harsh environments (and where operators use any separated from ground and will not vibrate and eventually
kind of equipment to hold or stand on) short out to ground
• Made to perfectly fit the application • Water proof design – built to last in uncovered environment
• Rigid military style connectors are securely fastened into • Repairable by MOTORETCH‘s assigned distributors in the
the stainless steel event of mechanically damage
138
AlphaRail – Wiring Rail System for Detonation Control – Wiring Rail
P/N Description
AlphaRail – Wiring Rail System for Detonation Control – Harness to connect Wiring Rail and DetCon20 Control Unit (1 per Rail required)
P/N Description Rail Connector Length
AlphaRail – Wiring Rail System for Detonation Control – Lead to connect Detonation Sensor and Wiring Rail (1 per Sensor required)
P/N Description Sensor Connector Rail Connector Length
43.30.016-L Sensor lead 2 pole socket, 180° 3 pole socket, 180° "L"= 10/20/30/40/60 in.
AlphaRail – Wiring Rail System for Detonation Control - Detonation Sensor (1 per Cylinder required)
P/N Description
MANAGEMENT
GAS ENGINE
75.10.280 Flat bar, 90°
1)
For packs of ten please add suffix "-10" to part number.
139
140
SENSOR SYSTEMS
The gas engine
Engine Industry
industry has changed rapidly over
during
thethe
last
last
couple
few years.
of years.
Modern
Modern
engine
Engine
control
Control
systems
Systems
call call
for for
reliable sensors supplying the data for temperatures, pressures or oxygen content. MOTORTECH offers a variety of
sensors that have a longer life expectancy and are made for industrial application rather than being automotive
MOTORTECH
origin. offers a variety of sensors that have a longer life expectancy and are made for industrial application
rather than being automotive origin.
141
SENSOR SYSTEMS
• Made of stainless steel which performs better than alumi- • Rails are filled with special foam to ensure that all wires are
num in harsh environments (and where operators use any separated from ground and will not vibrate and eventually
kind of equipment to hold or stand on) short out to ground
• Made to perfectly fit the application • Water proof design – built to last in uncovered environment
• Rigid military style connectors are securely fastened into • Repairable by MOTORETCH‘s assigned distributors in the
the stainless steel event of mechanically damage
142
AlphaRail – Wiring Rail System for Temperature Control – Wiring Rail
P/N Description
AlphaRail – Wiring Rail System for Temperature Control – Harness to connect Wiring Rail and Junction Box (1 per Rail required)
P/N Description Rail Connector Length Equivalent to
AlphaRail – Wiring Rail System for Temperature Control – Thermocouples with Lead and Rail Connector (1 per Cylinder required)
P/N Description Rail Connector Length Equivalent to
56.01.180-L / -K 1)
Thermocouple, 180° 3 pole pin, 180° "L"= 10/20/25/30/40/60 in.
56.01.090-L / -K1) Thermocouple, 90° 3 pole pin, 180° "L"= 10/20/25/30/40/60 in.
1)
Comes with loose connector and 177 in. lead length.
SYSTEMS
SENSOR
143
SENSOR SYSTEMS
Modern gas engines are equipped with various kinds of The wiring has a central plug that is mounted on the engine
sensors that enable the operators to monitor, process and with a suitable bracket. MOTORTECH offers compatible har-
evaluate important data continuously, e.g. with an ALL-IN-ONE nesses to connect the engine controller.
gas engine management.
1)
Scope of supply and design depends on the type of engine.
MOTORTECH offers pre-configured sensor harnesses which
are designed individually for each type of MAN® engine. All
wires are embedded in a temperature-resistant and flexible
insulation. The harness is individually customized for each
type of engine, and therefore it is easy to install. The scope
of supply1) includes all sensors necessary for the operation of
the specific engine, and the following operational data can be
obtained:
144
Sensor Harnesses for MAN® Gas Engines – MAN® E0836LE202
P/N Description
SYSTEMS
P/N Description SENSOR
06.30.040 Harness with all sensors for MAN® E2842LE312
145
SENSOR SYSTEMS
146
Sensors
For several years MOTORTECH offers Oxygen sensors that A Heat shield can be screwed on top. This way the sensor
can be used as replacements for the OEM part. Shielded and does reach directly into the exhaust gas stream with all its
unshielded versions can be selected. deposits and the heat shield protects the sensor against tran-
To increase life time of these critical sensors, there is also a stain- sient temperature from the hot exhaust manifold.
less steel hub available that is welded into the exhaust pipe.
Oxygen Sensors for CATERPILLAR® G3400 and G3500 Series Gas Engines
P/N Figure Description Connector Length Equivalent
19.60.027 1 Oxygen sensor, non shielded 6 pole pin, 180° 10.00 in. 196-5391
19.60.029 2 Oxygen sensor, shielded 6 pole pin, 180° 51.00 In. 141-2494
06.30.110 Oxygen sensor harness 9 pole pin, 180° 90.00 in. A740735
19.60.007 3 UEGO oxygen sensor 8 pole pin, 180° 15.75 in. DL08311001
19.71.013 UEGO oxygen sensor lead 8 pole socket, 180° 79.00 in. DL08311003
SYSTEMS
SENSOR
1 2 3
147
SENSOR SYSTEMS
148
Thermocouples (Type-K) – For AlphaRails – Wiring Rail System for Temperature Control
P/N Description Rail Connector Length Equivalent
56.01.090-K 1)
Thermocouple, 90° 3 pole pin, 180° 177.00 in.
1)
Comes with loose connector and 177 in. lead length.
SYSTEMS
SENSOR
1229 9387 Thermocouple 620 series
149
150
GAS REGULATION
In many countries of the world, alternative fuels like biogases
bio gaseshave
havetaken
takenover
overto
tobecome
becomeaamajor
majorsource
sourcefor
for
electricity production with gas engines. Due to the constantly changing quality or varying BTU levels, the demand
for more sophisticated air/gas
Air/Gas mixing
mixing equipment
equipment hashas increased.
increased. MOTORTECH
MOTORTECH has has designed
designed aa line
line of
of ventury
ventury type
type
mixers, their electronic controls and butterfly valves (throttles) to control the gas engines in a more accurate way.
151
GAS REGULATION
Stepper Motor Card Flow Bodies Gas Inlet Flanges Outlet Flange Kits
152
VariFuel2 − Air/Fuel Ratio Mixer
Feature VariFuel2 – 100-50 VariFuel2 – 140-65 VariFuel2 – 200-100 VariFuel2 – 200-120
Air requirement 150-450 m³/h 450-850 m³/h 850-2300 m³/h 700-3200 m³/h
Please consult factory or your nearest MOTORTECH Distributor to get correct VariFuel2 design, specified for your engine application.
Questionnaire for VariFuel2 air fuel ratio mixer design.
D Engine power – kW
E Fuel
153
GAS REGULATION
154
VariFuel2 Air/Fuel Ratio Mixer – Flow Bodies
P/N Description Diameter VF2-100-50 VF2-140-65 VF2-200-100 VF2-200-120
155
GAS REGULATION
Gas Gas
VariFuel2 VariFuel2
A-Bank B-Bank
Air
156
VariFuel2 Air/Fuel Ratio Mixer – Accessories – Adjustment Tool for Belt Tension NEW
P/N Description VF2-100-50D VF2-140-65D VF2-200-100D VF2-200-120D
1)
Gaskets included in each outlet flange kit.
157
GAS REGULATION
158
EmCon5
MOTORTECH LEAN-BURN EMISSION CONTROLLER
Features
REGULATION
159
GAS REGULATION
Engine Run
GCB Closed
Gas Selection
Alarm/ Shutdown
MAT Warning
Mixer Warning
9-30 VDC Supply
ZERO Pressure
Gas Filter Regulator
Gas
CH4 optional
Load 0-20 mA
Mixer Control
Mixer Feedback
Throttle VariFuel2
160
EmCon5 Lean-Burn Emission Controller – EmCon5 Control Unit
P/N Supersedes Description
06.30.045 1 EmCon5 sensor harness including MAT sensor P/N 56.01.021 and MAP sensor P/N 56.02.017
REGULATION
GAS
1 2 3 4
161
GAS REGULATION
Throttles
MOTORTECH THROTTLES/BUTTERFLY VALVES
D
F
E B
ID
A H
162
Throttles for Naturally Aspirated and Turbocharged Engines – Standard – Series 50 (41 - 42 mm)
P/N Supersedes Description A B C D E F G H Inner Diameter
Throttles for Naturally Aspirated and Turbocharged Engines – Standard – Series 100 (48 - 68 mm)
P/N Supersedes Description A B C D E F G H Inner Diameter
Throttles for Naturally Aspirated and Turbocharged Engines – Standard – Series 140 (73 - 85 mm)
P/N Supersedes Description A B C D E F G H Inner Diameter
Throttles for Naturally Aspirated and Turbocharged Engines – Standard – Series 150 (82 - 104 mm)
P/N Supersedes Description A B C D E F G H Inner Diameter
Throttles for Naturally Aspirated and Turbocharged Engines – Standard – Series 200 (98 - 125 mm)
P/N Supersedes Description A B C D E F G H Inner Diameter
30.40.201-100 30.40.200-100 Throttle 180 mm 126 mm 260 mm 150 mm 12 mm 200 mm 11 mm 110 mm 100 mm
30.40.201-105 30.40.200-105 Throttle 180 mm 126 mm 260 mm 150 mm 12 mm 200 mm 11 mm 110 mm 105 mm
30.40.201-115 30.40.200-115 Throttle 180 mm 126 mm 260 mm 150 mm 12 mm 200 mm 11 mm 110 mm 115 mm
Throttles for Naturally Aspirated and Turbocharged Engines – Special – IMPCO® Replacement Series 100/1401)
REGULATION
Throttles for Naturally Aspirated and Turbocharged Engines – Special – Series 160 for CATERPILLAR® G3400 and G3500 Series
P/N Supersedes Description Inner Diameter Equivalent to
164
Gas, Safety
and Control Systems
Our Services
• Customized engineering
• Production in accordance
with relevant standards and
regulations • Lists of parts, documentation
and CAD drawings
• Gas Appliance Directive
• Tested functioning and leak-
• Pressure Equipment proofness (Factory certificate
Directive category II & I 2.1 according to EN 10204)
165
166
GAS ENGINE ACCESSORIES
Besides the key products like ignition, electronic controls, etc. MOTORTECH also offers several lines of accessory
products that help the operators to cut cost on a long term strategy. Automatic liquid refilling systems with adju-
stable alarm sensors as well as coolant and oil filters that are made from stainless steel and last for nearly ever.
This cuts the disposal cost of any operation and helps the environment.
167
GAS ENGINE ACCESSORIES
LLC
MOTORTECH LIQUID LEVEL CONTROLLER
Features
• Liquid level controller with built-in MIN level sensor • Liquid inlet shut off valve
• Adjustable MIN and MAX sensors allow direct connection to a PLC • Cover made of stainless steel
for switching a pump ON and OFF (optional) • Easy and quick installation
• 1/2 NPTF inlet and outlet ports • CSA Class I, Div 2, Group C, D
168
LLC – Liquid Level Controller – Base Unit
P/N Description
80.00.001-NC Base unit1) with NC (normally closed) / fail safe sensor, switch contact
1)
MIN/MIN-sensor build in. Includes sensor lead.
LLC – Liquid Level Controller – Sensor Kits – 1 - 3 Kits can be added to Base Unit1)
P/N Description
2
PLC
1
3
158 mm
280 mm
7
14,15 mm
5
4 20 mm
185 mm
1 Vent outlet connection 1/2 NPTF 4 Liquid outlet connection 1/2 NPTF 7 MIN sensor adjustable
2 Optional vent outlet 5 MIN sensor 8 Liquid supply tank
connection 1/2 NPTF 6 MAX sensor adjustable
ACCESSORIES
GAS ENGINE
169
GAS ENGINE ACCESSORIES
CoolantFilter
MOTORTECH CUSTOM MADE STAINLESS STEEL FILTERS
mobile
stationary
• Increases water pump life is circulated through the engine block. Contami- • Inhibits scale deposits on all coolant passages
nants and suspended solids in the coolant act as and interior thermal surfaces of the engine block.
• Reduces coolant deposits and increases cylinder
a conductor, which more readily allows current to
head efficiency and life
flow throughout the engine block, which degrades
• Stainless steel filter elements can be cleaned –
EPDM, buna, rubber, viton, and soft metal or alloy
NO WASTE
components / water pump bearings, impellers,
• Visual flow indicator (stationary applications)
etc.
• Easy to service – decreases maintenance cost
• Cleaned coolant inhibits corrosion on engine com-
• Filter micron rating: ponents such as cylinder heads, cylinder liners
standard – 50 micron and seals, water pump impellers and bearings,
optional – 25 micron etc.
• Flow rate up to 30 GPM
170
Coolant Filters – Stationary Applications – Standard (for Temperatures up to 200 °F / 95 °C)
P/N Description Element Outside Diameter Element Length Micron Rating1) Stand Flow Indicator Application
25.00.009-50-30 Coolant filter 5.00 in. 9.00 in. 50 30.00 in. x stationary
25.00.018-50-49 Coolant filter 5.00 in. 18.00 in. 50 49.00 in. x stationary
Coolant Filters – Stationary Applications – High Temperature (for Temperatures 200 °F / 95 °C up to 400 °F / 205 °C)
P/N Description Element Outside Diameter Element Length Micron Rating1) Stand Flow Indicator Application
25.00.009-50-30-HT Coolant filter 5.00 in. 9.00 in. 50 30.00 in. x stationary
25.00.018-50-49-HT Coolant filter 5.00 in. 18.00 in. 50 49.00 in. x stationary
25.00.408-50-ST Coolant filter 4.00 in. 8.00 in. 50 24.00 in. mobile
25.00.409-50-ST Coolant filter 5.00 in. 9.00 in. 50 24.00 in. mobile
25.00.409-50-FI-ST Coolant filter 5.00 in. 9.00 in. 50 24.00 in. x mobile
25.00.418-50-ST Coolant filter 5.00 in. 18.00 in. 50 24.00 in. mobile
25.00.109-50 Coolant filter element 5.00 in. 9.00 in. 50 stationary / mobile
25.00.118-50 Coolant filter element 5.00 in. 18.00 in. 50 stationary / mobile
171
GAS ENGINE ACCESSORIES
Stainless steel micronic wire cloth available in micron ratings of 3-400 absolute. Welded serial #, ID tag
304 or 316, 20-gauge stainless steel perforated inner / outer tube 3/16 in. on 1/4 in. centers
Seals available in Buna-N, HSN, Teflon and Viton to suit your application
172
Stainless Steel Lube Filters – Element Kits1)
Element Outside Element Micron Number of
P/N Description Application Equivalent to
Diameter Length Rating Elements
25.00.300-1-CA Lube filter element kit 7.00 in. 30.00 in. 38 1 CATERPILLAR® G3508/12/16
25.00.301-6-CA Lube filter element kit 7.00 in. 13.00 in. 38 6 CATERPILLAR® G3606/08/12/16
25.00.303-1-CA Lube filter element kit 5.00 in. 9.00 in. 38 1 CATERPILLAR® G3406/08
25.00.310-4-WA Lube filter element kit 3.00 in. 15.00 in. 25 4 WAUKESHA® 167602B
25.00.310-7-WA Lube filter element kit 3.00 in. 15.00 in. 25 7 WAUKESHA® 167602B
25.00.310-14WA Lube filter element kit 3.00 in. 15.00 in. 25 14 WAUKESHA ®
167602B
25.00.311-4-WA Lube filter element kit 3.00 in. 30.00 in. 25 4 WAUKESHA® 168660B / 489493
25.00.311-7-WA Lube filter element kit 3.00 in. 30.00 in. 25 7 WAUKESHA® 168660B / 489493
25.00.312-1-WA Lube filter element kit 5.00 in. 7.00 in. 75 1 WAUKESHA ®
208472B / 489488
25.00.313-1-WA Lube filter element kit 5.00 in. 10.00 in. 75 1 WAUKESHA® 208472C / 489489
25.00.314-10-WA Lube filter element kit 3.00 in. 30.00 in. 25 10 WAUKESHA® 168660H
25.00.320-3-WS Lube filter element kit 4.00 in. 18.00 in. 25 3 WHITE SUPERIOR 6G/GT/GTL/
®
GTLA-B
25.00.320-4-WS Lube filter element kit 4.00 in. 18.00 in. 25 4 WHITE SUPERIOR® 8G/GT/GTL/
GTLA-B/SGTB
25.00.320-5-WS Lube filter element kit 4.00 in. 18.00 in. 25 5 WHITE SUPERIOR® 12G/GT/GTL/
GTLA-B/SGT/SGTA-B
25.00.320-7-WS Lube filter element kit 4.00 in. 18.00 in. 25 7 WHITE SUPERIOR® 16G/GT/GTL/
GTLA-B/SGT/SGTA-B
25.00.330-1-AR Lube filter element kit 4.00 in. 9.00 in. 38 1 ARIEL® A-661 / A-0661
1)
All steel lube filter element kits are supplied with a shipping case.
25.00.300-CA Lube filter element kit 7.00 in. 30.00 in. 38 25.00.300-1-CA CATERPILLAR ®
25.00.335-EMD Lube filter element kit 6.00 in. 30.00 in. 38 EMD ®
8345482
Locomotive Engines
174
Soak Tank Backwash Cabinet Drying Cabinet
• Durable powder coated finish • Powder coated finish • 4,800 Watt – 16000 BTU heating
• Inside tank dimensions • Slotted subfloor parts rack unit 210 V
48 in. x 20 in. x 16 in. • Water backsplash curtain • Durable powder coated finish
• 1,500 Watt screw in heat element • Adjustable parts rack • Inside cabinet dimensions
with built in thermostat • Solids sediment waste water 48 in. x 30 in. x 24 in.
• 110 Volt power requirements tank-3 stage • 30 minute timer
• Castor wheels for easy movement • High pressure washer not included • Hinged door with latch closures
of unit
• Hinged lid
• Recirculation pump with 30 minute timer
• Optional heated tank
175
INDEX
176
P/N Page P/N Page P/N Page
02.85.901. . . . . . . . . . . . . . . . . . . 75 02.85.928. . . . . . . . . . . . . . . . . . . 74 03.90.140. . . . . . . . . . . . . . . . . 157
177
INDEX
178
P/N Page P/N Page P/N Page
06.50.003. . . . . . . . . . . . . . . . . . . 31 06.51.136. . . . . . . . . . . . . . . . . . . 86 06.80.091. . . . . . . . . . . . . . . . . . . 35
179
INDEX
180
P/N Page P/N Page P/N Page
06.85.505-L . . . . . . . . . . . . . . . . . 58 06.85.839H-L. . . . . . . . . . . . . . . . 58 06.88.003-K. . . . . . . . . . . . . . . . . 60
181
INDEX
182
P/N Page P/N Page P/N Page
09.02.3000-L. . . . . . . . . . . . . . . . 62 09.02.7000-L. . . . . . . . . . . . . . . . 62 09.12.3000-L. . . . . . . . . . . . . . . . 63
183
INDEX
184
P/N Page P/N Page P/N Page
25.00.310-4-WA. . . . . . . . . . . . 175 259-2078 . . . . . . . . . . . . . . . . . . . 32 30.40.141-75-HT. . . . . . . . . . . 163
185
INDEX
186
P/N Page P/N Page P/N Page
44.04.005. . . . . . . . . . . . . . . . . . . 49 56.01.180-25. . . . . . . . . . . . . . 149 593054-L . . . . . . . . . . . . . . . . . . . 47
187
INDEX
188
P/N Page P/N Page P/N Page
75.30.100-1. . . . . . . . . . . . . . . . . 49 790314-1 . . . . . . . . . . . . . . . . . . . 51 95.01.020-L-3. . . . . . . . . . . . . . . . 80
189
INDEX
190
P/N Page P/N Page P/N Page
95.70.012-450. . . . . . . . . . . . . . . 46 A-661 . . . . . . . . . . . . . . . . . . . . 175 FMOS-1 . . . . . . . . . . . . . . . . . . . . 75
191
INDEX
192
P/N Page P/N Page P/N Page
SOR-500. . . . . . . . . . . . . . . . . . . . 70 USL2CL-"L"AIPS . . . . . . . . . . . . . . 62 USLA78SPB-"L"A . . . . . . . . . . . . . 63
USL2BL-"L"A. . . . . . . . . . . . . . . . . 61 USLA18T33-"L"A. . . . . . . . . . . . . . 63
USL2BL-"L"AIPS . . . . . . . . . . . . . . 61 USLA35SPB-"L"A . . . . . . . . . . . . . 63
USL2C-"L"A. . . . . . . . . . . . . . . . . . 62 USLA36SPB-"L"A . . . . . . . . . . . . . 63
USL2C-"L"AIPS. . . . . . . . . . . . . . . 62 USLA45SPB-"L"A . . . . . . . . . . . . . 63
USL2CL-"L"A. . . . . . . . . . . . . . . . . 62 USLA51SPB-"L"A . . . . . . . . . . . . . 63
193
YOUR WAY TO MOTORTECH
MOTORTECH GmbH
Hogrevestr. 21-23
29223 Celle
Phone: +49 5141 93 99 0
Fax: +49 5141 93 99 99
www.motortech.de
motortech@motortech.de
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